Question

Explain the thermoforming process. What are the process’s advantages and disadvantages? What type of part geometry is typically produced by this process?

Answer 1

Thermoforming is a method of processing cast or extruded plastic sheet into finished parts up to 0.500 inch thick. The raw material is heated to its specific thermoforming temperature and immediately shaped to the desired configuration.

Advantages:

• FAST production tooling available in as few as 2-3 weeks,
• Prototype tooling using cost effective molds
• Superior Aesthetics and Functionality
• Flexible Ordering with short lead times
• Compatible with a wide range of engineered thermoplastics

Disadvantages:

• Material distribution is difficult to control.
• Cannot produce as many parts.
• Highly detailed parts are difficult to achieve.
• Webs tend to develop around the mold from overheating.
• Absorbed moisture can expand, forming bubbles within the plastic.

Type of part geometry typically produced:

• Creating a product design with excellent and highly appealing part geometry may only be limited by creativity and inspiration. However, it is one thing to render an image of a flawlessly designed part or product, it can be quite another to manufacture such a design with the same elegant geometry,
• If aesthetic design, high quality part geometry, or brand differentiation are important to your project, you should consider the benefits of the heavy gauge thermoforming process.