Thermoforming products come in various materials and designs. Let’s explore what materials are used in the production process and their applications!
Thermoforming is a flexible and effective technique to create a wide range of items since it provides a lot of opportunities for creativity and design. Therefore, we can see thermoforming products in many industries.
This article will provide details on their types, materials, and applications. Let’s delve in!
1. What Are Thermoforming Products?
Thermoforming products refer to plastic products formed by the thermoforming method. It’s the process of molding thermoplastic sheets into different shapes using pressure or vacuum. Thin sheets are used to make cups, containers, lids, trays, and clamshells, while thicker sheets are used to make car doors, dashboard panels, refrigerator liners, and plastic pallets.
The process uses vacuum and pressure-forming techniques (depending on the project’s needs) to stretch hot thermoplastic across a mold’s surface. A plastic sheet is shaped inside a mold cavity. Each cavity is made to create a particular part, and the complete mold setup, or “tooling,” is made up of several cavities.
Thermoforming is perfect for quickly generating large volumes of molded goods since it just requires a few simple steps.
2. Types of Thermoforming Products
We can easily find plastic thermoforming products in many applications, including:
- Packaging products: blister packs, clamshell packaging, trays, containers and protective packaging
- Consumer goods: bins, boxes, tables, chairs, hairbrushes, combs, plastic cosmetic holders, toys, parts or covers for TV and kitchen appliances, and outdoor equipment.
- Industrial components: car parts (dashboard, bumpers, and trim), panels, enclosures, machine covers, custom molds, and prototypes.
- Medical devices: protective covers for sensors and thermometers, surgical trays, diagnostic kits, medical packaging, and single-use items (blister packs, diagnostic cups, or face shields).
3. What Materials Are Commonly Used In Thermoforming Products?
Manufacturers usually need the following materials to produce thermoforming products:
Common plastic materials
Depending on the project’s requirements, plastic manufacturers will use:
+ High-impact polystyrene (HIPS): the material has a high melting point, is easy to shape and form, and is inexpensive. Food packaging, plastic cutlery, toys, medical trays, refrigeration lining, and electronics insulation are just a few product examples using HIPS.
+ Polypropylene (PP): Because of its exceptional resilience to heat, stress, and chemicals, polypropylene (PP) is a common thermoforming plastic material used in toys, packaging, pipe systems, acid tanks, laboratory components, and reusable food containers. Although PP is lightweight, easily customizable, and unlikely to break, it is not as UV-resistant as some other thermoplastics.
+ Polyethylene terephthalate (PET): PET is frequently used in bottle manufacturing, packaging, and synthetic fibers. In the thermoforming process, it is an excellent choice because it provides resistance to chemicals, impacts, and tensile fracture. For PET plastic to be durable and resistant to substances like oxygen and water, it must be dried after molding. Additionally, it is among the most recyclable materials.
+ Acrylonitrile Styrene Butadiene (ABS): ABS is a strong, rigid thermoplastic that is resistant to impacts, chemicals, and ultraviolet light. It is composed of acrylonitrile, styrene, and butadiene. Additionally, it is elastic and flexible, which makes it an ideal choice for a variety of sectors, including 3D models and product prototypes, computer keyboard keys, baggage, toilet stalls, and automobile parts. It’s also a popular option because of its affordability and simplicity of production.
+ Polyvinyl Chloride (PVC): It’s an economical and flexible plastic used to produce shower curtains, plastic wraps, pipes, etc. Additives such as plasticizers and phthalates can be added to improve its qualities, and it can be used with cotton to make canvas material.
+ Acrylic: Acrylic is an easily thermoformed material that is transparent, flexible, and impact-resistant. It is perfect for heat shaping since it softens at high temperatures but doesn’t become liquid until around 320 degrees. Its applications include TV screens, furniture, aquariums, and windows for outdoor equipment.
Role of filler masterbatch
The thermoforming process uses the above resin to form plastic products. However, filler masterbatch has emerged as the best material option as a result of growing demand for affordable resources and concerns about the volatility of the global fossil resin market.
Filler masterbatch, also known as calcium carbonate filler, consists of CaCO3 powder, virgin resins, and specific additives. It offers numerous benefits to final plastic thermoforming products.
+ Enhanced properties: When filler masterbatch is added during thermoforming, the mechanical qualities of the finished products—such as their capacity to withstand tearing, friction, and slippage, as well as their dimensional stability, stiffness, impact strength, and printability—are increased, leading to better performance and a more appealing look.
+ Improved productivity: CaCO3 powder, the main ingredient of filler masterbatch, has good thermal conductivity. It helps increase production efficiency while conserving energy.
+ Cost efficiency: By replacing virgin resins and lowering reliance on fossil polymers, filler masterbatch reduces production costs.
+ Environmental benefits: Since calcium carbonate filler emits less carbon dioxide during production than fossil resin, it is a more ecologically responsible option. For thermoforming producers, it provides sustainable development, making it a perfect substitute for non-renewable resources and supporting sustainable growth.
Read more: What Is Filler Masterbatch? – A Complete Guide to Reducing Plastic Costs
4. How to Choose the Right Thermoformed Product For My Needs?
To choose perfect thermoforming products for your needs, you should consider:
- Your needs: When choosing consumer goods, people usually pay attention to their aesthetics and strengths. When it comes to industrial components, you should consider if the material can withstand high stress, heat, or chemicals.
- Materials: For example, if you need a sturdy and transparent food package, PET is ideal. Meanwhile, people usually go for HDPE for industrial components, packaging, and large containers.
- Design: Consider if you prefer a transparent or opaque design for privacy. Plus, some designs are more difficult to form, requiring suitable materials and precise molds and techniques.
- Cost: The materials identify the price of a product. For example, PET is commonly used for clear food containers and often costs less than PP material used for microwave-safe and dishwasher-safe containers.
- Environmental friendliness: It’s better to choose materials that are recyclable or biodegradable for sustainability. Eco-friendly materials include PET, HDPE, and PP.
5. FAQs about Thermoforming Products
- What industries commonly use thermoformed products?
Thermoforming products are present in many industries, including consumer products, packing, medical, automotive, and appliances.
- What are the advantages of using thermoformed products in consumer goods?
Consumer goods made from thermoforming plastics are usually lightweight, durable, and sustainable. The materials also support intricate designs and complicated shapes, offering various choices for manufacturers and users.
6. Conclusion
Thermoforming products can be made from various plastics and present in different industries. To choose the best products for your needs, you’d better consider your purpose, materials, designs, and costs.
If you’re a manufacturer of plastic thermoforming products and looking for a material option, visit EuP Egypt. We offer filler masterbatch solutions to save production costs and enhance the properties of the finished products, such as hardness, impact resistance, and printability.
Read more: Filler Masterbatch For Thermoforming: 4 Surprising Ways It Boost The Process
Don’t hesitate to contact us now for more details!
