Thermoforming transforms thermoplastics through a series of processes, including heat, vacuum, and pressure, applied to a plastic sheet material. It utilizes a variety of machines to produce plastic products, including high-speed in-line thermoforming lines with robotic automation, light-gauge roll-fed machines, and larger sheet-fed machines for heavy-gauge products. This process allows parts to be produced with lower production costs and may not require additional machining or tooling. It is a popular option for manufacturing components such as clamshells, blisters, automotive appliques, cases, reusable totes/trays, bumpers, and covers. Thermoforming is also an efficient way to create intricate shapes from plastic sheet while keeping costs low. The Thermoforming Process Thermoforming begins with plastic sheet, typically from .005” to .750” thick, that is heated and formed into the desired shape. This is done using a vacuum, air pressure, or mechanical force. After the plastic has cooled, it is trimmed, and any additional features (such as holes) are added using specialty tools such as high-speed CNC machining, high-precision robotic trimming, and routers. In many cases, with light-gauge inline thermoforming, the parts are finished and ready to use when they come off the machine. For heavy-gauge applications, the part can be used in its application once the desired modifications have been made. In either case, the same process can be repeated multiple times to produce batches of parts with identical shapes and sizes. Thermoforming Equipment Thermoforming requires specialized equipment to heat and form plastic sheet. At a minimum, this includes an oven, a vacuum source, and a forming tool. The oven is used to heat the thermoplastic until it is malleable enough to be shaped by the vacuum over or into the forming tool. Thermoforming Materials Thermoplastics are known for their durability, strength, and resistance to heat and chemicals, making them ideal for many applications. Thermoforming is often used with different types of thermoplastics, including variations of ABS (Acrylonitrile Butadiene Styrene), HIPS (high impact polystyrene), PET (polyethylene terephthalate), and PVC (Polyvinyl Chloride). These materials are available in various colors and can be modified to meet specific requirements. Thermoforming Applications Thermoforming is used in various industries, including medical, automotive, consumer products, and aerospace. This process offers them great flexibility in terms of shape and design possibilities. Here are thermoforming’s most common applications per industry: Medical: medical device trays, unit dose packaging, blisters, and transport trays. Automotive: interior and exterior appliques and trim components, mud flaps, and dunnage/tray systems. Consumer products: clamshell and blister packaging, gift sets, warehouse club packs, and Point-Of-Purchase (POP) displays. Electronics: ESD packaging, assembly systems, handling trays, inventory control systems, and Radom or cellular antenna components. Thermoforming continues to evolve with advances in technology and materials science. As new thermoplastics become available, manufacturers can create more intricate shapes while keeping production costs low. It’s an efficient way to create complex products from plastic sheet and will continue to be an important process serving many industries. Advantages of Thermoforming Thermoforming has become a popular choice for manufacturing many products, serving a variety of industries. This is because the process offers several advantages compared to other forming techniques. Cost-Effective With shorter design and tooling lead times and less expensive tooling, thermoforming can be a cost-effective solution for manufacturers. Versatile Thermoformed parts can be created in almost any shape with a wide range of materials and colors. This makes it ideal for applications that require complex shapes or unique finishes. Durable Thermoplastic materials are known for their strength and resistance to heat, chemicals, and impacts. This makes them suitable for use in harsh environments where other materials may not hold up over time. Jamestown Plastics Thermoforming Services Thermoforming is a reliable and efficient way to create custom parts for many industries. Its cost-effectiveness and versatility make it an increasingly popular choice for manufacturers. Get high-quality and reliable thermoforming services from Jamestown Plastics! With our experience and dedication to our clients, your thermoforming needs are in good hands. Contact us today to learn more about our thermoforming services! We look forward to working with you.
Heavy Gauge vs. Light Gauge Thermoforming Thermoforming is a versatile and cost-effective manufacturing method to create plastic parts and products. One key consideration in the process is choosing between heavy gauge and light gauge materials, which refer to the plastic sheet’s thickness. Both options have distinct benefits, contingent upon the specific project application and requirements. In this blog article, we will examine [...]
Automotive Thermoforming Applications As the automotive industry continues to evolve, the need for fuel-efficient and lightweight vehicles has grown exponentially. This has led to a renewed interest in thermoforming, a technique that has existed since the 1940s. It is the process of producing parts by heating thermoplastic sheet material until it becomes pliable, then forming it into a [...]
Reshoring and Nearshoring In recent years, global supply chains have encountered challenges such as trade conflicts, political volatility, natural calamities, and the COVID-19 pandemic. Consequently, numerous companies in the United States have had to reconsider their supply chain approaches. For instance, some are halting decades of outsourcing and offshoring by bringing their production back home or closer to [...]
Buffalo Business First: Clamtainer® revolutionizes packaging industry Buffalo Business First: It’s an exciting time at Jamestown Plastics, thanks to a brand-new product line with a catchy name and an innovative design that continues this company’s reputation for excellence. Clamtainer is a game changer in the field of transparent “clamshell” packaging and a vast improvement over flimsy traditional methodologies. Retailers and consumers alike are [...]
Choosing the Right Plastic Products Manufacturing Partner Click to ExpandPlastic is one of the most preferred manufacturing materials due to its durability and ductility, with different components used in the medical, automotive, electrical, aerospace, marine, and construction industries. In particular, the plastic thermoforming process has upsides over other plastic, metal, and FRP manufacturing techniques, including low tooling costs and faster product development. Establishing [...]
Electronics Thermoforming Applications While the origin of thermoforming can be traced back to the 19th Century, it was the mid-20th century when it was first introduced to the electronics sector. The process entails heating plastic sheet and shaping it into a specific form to manufacture various electronic products or packaging for those products. This approach has revolutionized the [...]
Medical Thermoforming Applications Thermoforming is a versatile manufacturing process that entails heating plastic sheets to a malleable state and then forming it with molds. Its significance in the medical field stems from its ability to produce cost-effective, lightweight, and disposable products that meet stringent quality requirements. Moreover, its accessibility, dependability, and efficacy make it indispensable for delivering safe [...]
Clamshells vs. Blisters Packaging is often the first point of contact between a customer and a product. As such, it can impact consumer perceptions. Therefore, choosing the most suitable type of packaging that protects the product and conveys the brand’s message effectively is essential. Clamshells and blisters are two popular packaging types that can provide various benefits, from [...]
Reduce, Reuse, and Recycle: How to Incorporate the 3R’s Into Any Business That Deals With Plastics There is a lot of plastic in the world, with 31.9 million metric tons of plastic waste being improperly disposed of globally. Luckily, green packaging is making an indent in our society, but until it’s fully implemented, it is important to do the most we can, at both a manufacturer and consumer level, to reduce [...]
The Ultimate Guide to Plastic ManufacturingIn the plastics industry, each polymer option presents unique mechanical characteristics. As a result, it is possible to fabricate almost anything with every material, and most plastic manufacturing processes cover a vast array of product development requirements. In […]
Industries Leveraging Custom Plastic Thermoforming Plastic thermoforming has become increasingly popular as a top manufacturing process in various industries. Using heat and pressure to shape plastic sheet into proper forms provides an efficient and cost-effective solution for product manufacturing. Moreover, it presents numerous benefits over alternative manufacturing methods, including decreased tooling costs and improved material efficiency. Here are some of the [...]
Understanding the Plastic Manufacturing Process Click to Expand Plastic is a versatile material that can be molded into a wide range of shapes and sizes, making it ideal for various applications. From food packaging and containers to medical equipment and car parts, plastic manufacturing plays a crucial role in the production of items. The process begins with the selection of raw [...]
Why Thermoforming Could Be The Best Choice For Manufacturing Your Product Click to ExpandThis blog will cover the basics of thermoforming and how it helps different industries stay on top of the market with its practical and financial benefits. What Is Thermoforming? Thermoforming transforms plastic sheet into a 3-dimensional shape using heat, vacuum, and pressure. In this process, plastic is heated to its softening point and then [...]
