Plastic Thermoforming

Plastic Thermoforming: Customized Solutions for Engineered Plastics that are Reliable and Accurate

Plastic thermoforming is a proven process for producing three-dimensional parts from flat, plastic sheet materials with high accuracy and strength. From medical trays and packaging to machine housings and automotive parts, plastic thermoforming is a reliable, scalable, and cost-effective process for producing custom plastic parts.

Welch Plastics offers custom plastic thermoforming services across diverse industries including medical, food packaging, retail, aerospace, and industrial manufacturing. Whether you are looking for a prototype or a large production quantity, our skilled staff will provide precision-formed components tailored to your needs.

In this article, we will discuss everything you need to know about plastic thermoforming: what it is, how it works, what types of plastic are used, and why it is the process of choice for so many manufacturers.

What is Plastic Thermoforming?

Plastic thermoforming is a manufacturing method to heats a flat sheet of plastic to a temperature that allows it to be pliable and shapes it over a mold. Once the heated plastic conforms to the mold, the plastic sheet is cooled and cut into its final shape.

This method is very effective in forming lightweight, rigid, aesthetic plastic parts that have applications in many industries.

There are two main types of plastic thermoforming:

• Vacuum Forming: uses vacuum suction to pull the heated sheet onto the mold.
• Pressure Forming: uses vacuum and positive air pressure for deeper draw and finer detail.

Both plastic thermoforming methods are economical and flexible, and produce parts from prototyping to full production. 

The Plastic Thermoforming Process

At Welch Plastics, we have a proven, quality-controlled process for achieving consistent, reliable results:

• Design & Engineering

Our team collaborates with you to establish the part design. When developing the part, we discuss the preferences for the plastic material.

We use 3D CAD modeling and prototypes to verify dimensional accuracy.

• Tooling & Mold

We create durable aluminum or composite molds according to the part geometry.

The cost and time to create the tooling is much quicker and less expensive compared to injection molding.

• Heating the Plastic Sheet

The thermoformable plastic sheets are heated until they reach forming temperature, which is usually between 250°F to 400°F, depending on the specific material.

• Forming the Part

The softened plastic sheet is put over the mold and is formed using a vacuum or pressure.

We'll be able to achieve complex details, sharp edges, and Taylor undercuts!

• Cooling & Trimming

The part is cooled, taken out of the mold, and trimmed to specifications.

At this point, you can add any needed additional secondary services, such as drilling, labeling, assembly, etc.

Benefits of Plastic Thermoforming

Plastic thermoforming provides several noteworthy benefits over other methods of manufacturing, such as injection molding or CNC machining:

1. Economic Tooling

The tooling for thermoforming is pretty basic and costs relatively speaking less to manufacture—great for prototypes, startups, or medium-scale production.

2. Quick Turn

Compared to injection molding, thermoforming provides faster lead times on tooling and faster production cycles on product.

3. Design Flexibility

Thermoforming can produce a wide variety of shapes, sizes, finishes, colors, and textures. And with thermoforming, we can creatively create complex geometries and branding features directly into the mold.

4. Scalable Production

Thermoforming works for small custom batch runs and high-volume productions with the same quality part produced every time.

5. Efficient & Sustainable Use of Material

Thermoforming creates some usable waste and many materials can have their material recycled where it can. You will often have the capability to re-use trimmed scrap for another production run.

6. Lightweight, Durable Parts

Thermoformed plastics have good impact resistance and dimensional stability with a great strength-to-weight ratio.

Typical Applications for Thermoformed Plastic Parts

Plastic thermoforming and formed plastic parts are used in almost every industry. Some typical applications to consider:

• Medical: Surgical trays, packages for medical devices, equipment paneling in hospitals.
• Food Packaging: Deli containers, clamshells, food trays, utensils.
• Automotive: Interior panels, underbody covers, dashboards, air ducts, etc.
• Industrial: Equipment housings, shields, and control paneling.
• Consumer Goods: Custom packaging, electronics housings, display cases.
• Retail & POP Displays: Signage, dispensers, product trays.
• Aerospace: Light paneling, bins, component trays.

Types of Plastics Used in Thermoforming

Having the right material will play a large part in the achievement of performance and durability. Welch Plastics will support you in the choice of material for your application.

Material Properties Applications

• ABS: Impact Proof, easy to form, Automotive panels, and housings.
• PETG: Clear, FDA Approved, tough Medical trays, packaging.
• HDPE: Chemical resistant, lightweight Industrial containers, tanks.
• HIPS: Cost-effective, printability, Displays, signage, packaging.
• PVC: Flame retardant, tough Equipment paneling, signage.
• Polycarbonate: Clear, extremely durable Machine Guards, security paneling.
• Acrylic (PMMA): Clear, UV-resistant displays, signage, and light covers.

Is Injection Molding Better Than Thermoforming?

 

Category	Thermoforming	Injection Molding
Tooling Cost	Cheaper	More Expensive
Lead Time	Faster	Slower
Volume	Small-Medium	High
Part Complexity	Medium to High	High
Material Waste	Less	Medium
Design changes	Easier	Costly

 

If you need prototypes quickly, one or small-medium runs, and respectable tooling costs, then plastic thermoforming is probably the way to go.

Why is Welch Plastics the Right Choice for Plastic Thermoforming?

At Welch Plastics, we combine decades of experience with new thermoforming technology to create plastic products that fulfill your requirements, both functional and aesthetic.

Here are some of the things that we do that make us different:

• In-house design and engineering
• Next generation vacuum and pressure forming equipment
• Full range of processing - prototypes to full runs
• Stringent quality control and ISO validated processes
• Quick Turnaround time
• Tooling and Custom Tooling and Secondary Assembly Services
• Material selection assistance

We work with clients in the medical, industrial, retail, and technology sectors who are seeking to develop solutions that meet their performance, availability, and budget criteria.

Frequently Asked Questions (FAQ)

What is the minimum order quantity for plastic thermoforming?

We will consider flexible minimum order quantities for prototypes and small to medium-sized production runs.

Do you assist with the design of the product?

Yes. We are a full-service CAD design, prototypes, and DFM (design for manufacture) company.

How long will the tooling lead time take?

Tooling lead time is generally 2-4 weeks (depending on part complexity and there may be an option to expedite).

Can you recycle the thermoformed part?

Yes, most thermoforming grade plastics are recyclable. We also try to minimize waste and wherever possible, will reuse any trims that we do not need to diminish wastage.

Is plastic thermoforming FDA and ISO compliant?

We can offer materials and processes that, if required, grant you compliance with FDA, ISO, and UL.

Obtain a Free Quote for Plastic Thermoforming Services

Whether you need a custom thermoformed product or you would like to scale on an existing design, Welch Plastics will be your resource for custom plastic fabrication and will provide you with a full turnkey solution from idea to the delivery of your product on time and within budget.

📞 Call (702) 240 - 9668

📧 Email info@welchplastics.com

Get your free quote today so we can turn that plastic product idea into a reality!