Thermoforming

The thermoforming process has been extensively studied in industry due to its low cost and good formability. In this process, a plastic sheet is heated to a pliable forming temperature, formed into a specific shape in a mold, and trimmed to produce a usable product. The thermoforming process is typically divided into thin-gauge and thick-gauge markets. Thin-gauge markets tend toward disposable products, such as blister packs, meat trays and drink cups. Thick-gauge markets tend toward permanent or industrial products and are typically used in transportation, medical, recreation, electronic and storage applications ^[1].

Today, the thermoforming process has become one of the fastest growing segments of the plastics industry. This has been brought about by the development of new materials and technologies, coupled with innovative production and specialized equipment capable of providing the manufacturing efficiency for the industry. As a pioneer in the plastics manufacturing industry, Alfa Chemistry has the ability to provide customers with unparalleled thermoforming solutions to meet the different needs of all walks of life. Please feel free to get in touch with us if you have a need.

Our Thermoforming Capabilities

Depending on the complexity of the part and the specific requirements of the application, different thermoforming processes can be selected. Alfa Chemistry's thermoforming capabilities are primarily as follows:

• Vacuum Forming

Vacuum forming is one of the oldest and most common methods of processing plastic materials. During the vacuum forming process, the plastic sheet is heated and then pulled around a single mold using suction. This method is an economical process for producing large-size and low-volume parts at a reasonable price.

• Pressure Forming

Pressure forming is an enhancement to the vacuum forming process. The process similarly involves heating a plastic sheet and using a vacuum to pull air away to force the sheet against the mold. In addition, a pressure box will be added to the non-mold side of the sheet. The pressure box creates up to 60 pounds per square inch (PSI) of air pressure. The extra pressure results in sharp detail.

• Drape Forming

The drape forming process is used for products that require a gradual curve. Without the use of a vacuum, a heated sheet of extruded plastic is manually draped over a mold to create the desired shape. Since the thickness of the material can be maintained, the process does not result in weaknesses in the part.

• Others

In addition to the above thermoforming capabilities, we can also provide mechanical forming, matched mold forming, twin sheet forming and billow forming.

Our Thermoforming Materials

You can choose from the following different thermoforming materials for your project.

Materials	Thermoforming processes	Applications
ABS, PP, PMMA, PVC, PET, LDPE	Vacuum forming, pressure forming, matched mold forming, twin sheet forming, mechanical forming;	Packaging
ABS, PS, PVC, PP, PC	Vacuum forming, pressure forming, mechanical forming;	Household and consumer goods
PC, PMMA, HDPE, LDPE	Pressure forming, drape forming, match mold forming,;	Automotive interiors and components
LDPE, PC	Vacuum forming, pressure forming, mechanical forming;	Healthcare and medical devices
PVC, HDPE, PC	Vacuum forming, pressure forming, drape forming, mechanical forming;	Construction and plumbing

If you are interested in our thermoforming process, please contact us immediately.

Reference

1. Throne J. Thermoforming. Applied Plastics Engineering Handbook. 2021, 345-375.