THERMOFORMING

WHAT IS THERMOFORMING?

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Thermoforming, also known as vacuum forming, is a method of creating plastic products that utilizes heat and pressure. The thermoforming process includes the following steps:

  1. The thermoforming machine heats a plastic sheet to soften it and make it pliable
  2. The pliable plastic sheet is stretched over a mold
  3. A means of pressure (usually vacuum) is used to force the sheet over or into a temperature-controlled mold
  4. The sheet is cooled to room temperature to retain the desired shape
  5. The thermoformed/vacuum-formed product is machined using specialized equipment to finalize the usable product

Thermoforming can be used to create a variety of products such as:

  • Automotive parts
  • Aerospace parts
  • Medical equipment
  • Building and construction equipment
  • Recreational equipment
  • Returnable dunnage
  • Aircraft components
  • Material handling equipment
OUR THERMOFORMING CAPABILITIES

At Cooper Plastics, we have all the necessary equipment to guarantee quality and consistency. We have mastered the science of thermoforming to produce consistent, reliable products every time. Below is an overview of Cooper Plastics thermoforming capabilities.

OUR MATERIALS

Cooper Plastics fabricates sheet thermoplastic materials into thermoformed/vacuum-formed plastic products. Below is a list of materials our company typically uses.

  • HDPE is our primary material
  • Other acceptable materials: HIPS, ABS, TPO, PC, PC/ABS, PETG, PP
  • Sheet L & W determined by platen size
  • Maximum Part Size = 96” x 172”

The choice of materials in thermoformed/vacuum-formed plastics is critical to ensure the final product has the durability, functionality, and aesthetic appeal you desire. Each material offers unique properties such as UV resistance, flame retardancy, or environmental sustainability.

For instance, ABS offers exceptional strength and impact resistance. Similarly, HIPS provides a balance of rigidity and toughness. PETG is often used in food packaging and medical device applications because of its properties of clarity and chemical resistance.

Leading vacuum-forming companies like Cooper Plastics will collaborate with you to help you identify the material that makes the most sense for your unique needs. We will use our knowledge and experience to manufacture high-quality plastic components and products that satisfy your specifications, performance needs, and budget.

OUR THERMOFORMING MACHINES

Thermoforming companies like Cooper Plastics use cutting-edge equipment to achieve consistent, high-quality results. Thermoforming machines come in various types and are used to precisely shape and mold plastics.

  • Thermoforming
  • Thermoforming
  • Thermoforming
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  • Thermoforming

These machines are simple and efficient. They work by heating a plastic sheet until it becomes pliable. Then, vacuum pressure is used to draw the sheet over a mold, creating a precise shape. Twin-sheet vacuum-forming machines can form two sheets simultaneously, creating hollow, double-walled parts with enhanced structural integrity.

The capabilities of the different machines enable vacuum-forming companies to produce a variety of products quickly and consistently, from simple plastic storage trays to intricate automotive parts to heavy-duty plastic pallets.

Learn more about our machines below.

  • ATM
    – 6′ x 10′ platen
    – 4-Station
    – Twin sheet capable
    – Load/unload automated
  • MAAC
    – 5′ x 9′ platen
    – 3-Station
    – Twin sheet capable
    – Top sheet max size = 40” x 90”
  • ATM
    – 9′ x 16′ platen
    – Single sheet
    – 3-Station
    – Load/unload automated
  • ATM
    – 5′ x 10′ platen
    – 3-Station
    – Twin sheet capable
  • Modern
    – 5′ x 9′ platen
    – Single sheet
    – 4-Station

VALUE ADDED SERVICES FOR YOUR PROJECT

At Cooper Plastics, we offer numerous other value-added services in addition to our thermoforming service. These services, which include product development, finishing, assembly, and more elevate the experience for our customers. It’s just another benefit of partnering with us!

HOW DO THERMOFORMING COMPANIES/VACUUM-FORMING COMPANIES MAKE PRODUCTS?

Thermoforming companies/vacuum-forming companies transform sheets of plastic material into a variety of products using a process that blends heat, pressure, and precision. The thermoforming/vacuum forming process starts with a plastic sheet that is fed into the thermoforming machine. The sheet is heated to a specific temperature to make it pliable and ready for shaping. The heated sheet is then draped over a mold and a vacuum is used to pull it tightly against the mold to capture every detail.

Next, the plastic is cooled until it solidifies. Finally, the thermoformed part is removed from the mold and trimmed to remove any excess material. This last step ensures the product is free of imperfections and meets the desired specifications.

HOW TO IDENTIFY QUALITY THERMOFORMING COMPANIES

How do you identify quality thermoforming/vacuum-forming companies? Modern vacuum plastic forming should be done by a company that can demonstrate expertise, reliability, and a commitment to excellence.

Industry experience is a top indicator of quality. A company with an extensive track record is likely to have honed its manufacturing processes, built strong relationships, and demonstrated the ability to adapt its technologies and procedures as the industry evolves. Look for a company that showcases a diverse portfolio of success in fabricating custom vacuum-formed parts. This proves the company’s ability to provide vacuum-forming solutions using different materials, designs, and complexity levels.

Another way to identify a quality thermoforming company is if it uses a diverse range of sophisticated equipment to meet the unique demands of customers. The best thermoforming companies invest in state-of-the-art machines that enable consistent quality and timely project completion. Additionally, consider the quality control measures that are in place that prove that customer satisfaction is a high priority.

Want to know what makes Cooper Plastics an industry leader in thermoforming? Learn more about our company and how we provide innovative solutions for our customers.

HOW MUCH DO THERMOFORMING COMPANIES CHARGE?

The cost of vacuum-forming plastics depends on things such as the complexity of the product design, the material used in the plastic sheets, and the size of the production run. Add-ons like drilling, assembly, and testing add value to the project but also come with added expenses.

Make sure you communicate with the thermoforming companies you are considering and have them provide a detailed quote for your project. They should be transparent with the costs so you can make an informed decision about how to proceed.

Want to partner with us for your thermoforming needs? Request a free quote or contact us for more information.