The Ultimate Guide to Plastic Thermoforming: Everything You Need to Know

Plastic thermoforming — what is it, why you would use it, and how to do it right. Plastic thermoforming can provide tailored, durable, and versatile products for anyone — in packaging, automotive, medical or retail. So read on in this ultimate guide for everything you need to know about plastic thermoforming, including benefits, the thermoforming process, applications, and how to choose a thermoforming company for your next project. 

Plastic Thermoforming: What is it? 

Plastic thermoforming is a manufacturing process in which a plastic sheet is heated to a pliable forming temperature and molded to a specific shape using vacuum pressure or mechanical force. Once the plastic has formed itself to the mold, it is cooled and trimmed to form the part.

Plastic Thermoforming Types

There are two types of plastic thermoforming —

1. Vacuum Thermoforming – It uses suction to pull the heated plastic sheet over a mold that creates a precise shape.
2. Pressure Thermoforming — This applies additional pressure in order for the plastic sheet to better match the mold, creating finer details and higher quality parts.

The Advantages of Plastic Thermoforming

Plastic thermoforming is a popular manufacturing process for many reasons:

• Low-Cost Production: Tooling is cheaper than injection molding.
• Versatility: Can be shaped into many shapes and sizes.
• Rapid Production: Fast production cycles; perfect for prototypes and short-run production.
• Lightweight & Durable: Thermoformed plastics are lightweight yet strong.
• Customization: Enables complex designs, branding, and functional improvements.

The Process of Plastic Thermoforming

Plastic thermoforming process consists of several steps, which are discussed as follows:

1. Selection of Material – Material selection is essential and differs based on an application (e.g. ABS, PETG, PVC, HDPE).
2. Sheet Heating – This may refer to the process of heating the plastic sheet to a temperature necessary for forming.
3. Forming Process – The heated sheet is shaped via vacuum or pressure.
4. Cooling & Trimming – The plastic shape cools and excess plastic is trimmed off.
5. Finishing & Quality Control – Final inspections and secondary processes (such as painting and assembly), as well as quality assurance measures, are performed to deliver a flawless product.

Typical Versatile Applications of Plastic Thermoforming

Plastic thermoforming is an industry-cohesive process that is utilized in multiple industries for its versatility and functionality. Here are some of its most common applications:

1. Packaging

• Blister packs
• Clamshell packaging
• Custom trays for product protection

2. Automotive

• Dashboard panels
• Door liners
• Bumper components

3. Medical & Healthcare

• Medical trays
• Device housings
• Sterile packaging

4. Retail & Displays

• Point-of-purchase displays
• Signage
• Store Fixtures

5. Industrial & Manufacturing

• Equipment covers
• Custom enclosures
• Protective cases

Factors to Consider When Choosing a Plastic Thermoforming Company

Choosing an appropriate thermoforming company to partner with is critical to producing quality products in a timely manner. Here are some important things to keep in mind:

1. Experience & Expertise

Seek a thermoformer that has proven itself successful in your industry and with your types of products.

2. Custom & Material Selection

Look for a company that provides plastic parts with diverse material choices and customization options as per your requirements.

3. Advanced Technology & Equipment

Employing modern equipment ensures precision, efficiency, and an ability to handle complex designs.

4. Competitive Pricing & Turnaround Time

Requesting quotes and lead times enables you to balance affordability with quality.

Ability & Efficiency

The ability of a manufacturer to do what you need of them efficiently is the key to getting the job done right. 

Plastic Thermoforming Sustainability

Many thermoforming companies offer eco-friendly options because of the increasing focus on sustainability:

• Recyclable Materials – Materials available in PET, HDPE, and other recyclable plastics.
• Biodegradable Materials – There are plastics that decompose naturally over time.
• Manufacture Energy Efficiently – Less waste produced and more efficient use of energy during manufacturing.
• Closed-Loop Recycling — caring plastic waste.

Conclusion for Plastic Thermoforming

Thermoforming is an affordable and flexible custom product solution whether you require custom packaging, automotive parts, medical components, or retail displays. Picking the right plastic thermoforming business means getting high-quality products that meet your requirements and specifications in addition to sustainability efforts. 

Need A Plastic Thermoforming Quote?

If you’re in the market for a dependable plastic thermoforming partner, reach out to us today and tell us about your project needs!

Examples of our Thermoforming projects

(Custom serving trays thermoformed in one piece using a mold)

(Thermoformed globes used as hanging lampshades.  These 30+ lampshades were installed at a property in NYC)

David heat forming a large clear acrylic dome using forced air after heating of the acrylic.

Angel, David and David Jr prepping and welding a dome, and the finished product ordered by a client in Chicago.