Thermoforming Plastics In Industrial Applications

Broadly speaking, if you are in an industry that is into production, there is a good chance that you might come across the use of thermoforming sheets or thermoforming materials to make some of those things. This versatile process is famous in the manufacturing industry for its being cost-effective and the relative simplicity and benefits it provides.

To simply put, it’s a catch-all term that refers to any process that uses a heated sheet of thin plastic and then forms over a mold in the development of a product or part. Thermoforming is a process used in the manufacturing of shapes and covering and not an end-to-end solution. The plastic sheet made from the process can take the shape of the mold when it comes in contact with it and help to create components for other products like coverings.

In addition, it depends on the use and the application of the sheets, how intricate the design and curves are, what finish is required, and what material should be used.

Popular applications of Thermoforming plastic:

Thermoforming with its versatile process will work in just about every industry, from food packaging to aerospace to auto parts manufacturing. Most industries find themselves using the thermoplastics at one point or another, so understanding these is vital. There are two types of sheets produced for different purposes, thin and thick gauge. Thin-gauge sheets are mostly used in packaging that is required to be rigid and disposable, while when it comes to thick-gauge sheets, those have several uses. Thick-gauge thermoforming sheets are typically used for permanent surfaces on automobiles, window enclosures, building products, signs, and electronic equipment.

There is no limit to the huge amount of applications for plastic products that are thermoformed. But these sheets are not a one-size-fits-all approach. The materials used, specific services or processes, and skills of the plastic material used to come together to create the perfect applications for thermoforming.

These thermoforming sheets with non-composites have some exciting process developments that can add value to specific industries and their applications. Also, applications of thick sheets are converted to composite sheets which can result in thinner-walled parts and therefore can be ideal for application which involves weight-sensitive factors.

Heating and Forming it to required design:

Before making it into a sheet, every project starts with a design. Based on the design and the requirement the plastic is thermoformed into a larger product. Often the outer layer is designed according to the aesthetic covering, texture, and look required for a piece of equipment. Whatever you want to use for, a qualified and experienced expert can work with you to refine your ideas into a shape and texture that will work with your process and other interior used for the same application.

Material selection plays an important role!

There is where most assistance is needed to determine which type of plastic material will be best suited for the project. Depending on the factors like production run, environmental factors, size of the product, physical properties, will help the professional decide and recommend the right plastic material for either aesthetic and functional reasons.

With the unique properties and benefits that come with each material, thermoforming allows for a selection of colored and textured materials for specific applications that can greatly enhance the appearance suitable for specific applications and impact the look and design of the final product. Some of the factors that you can help the professional offer you a suitable solution are as follows:

●      Consider if you need the part to be rigid or have some flexibility.

●      Think about the budget you have and how much would you like to spend.

●    What is more important? Being on a budget or choosing the best qualities and material?

●      Will the ready part, will have some graphics, text, or paint on it?

A Simple Guide to Decorative Thermoplastic Material

Many engineers look upon decorative plastics and thermoplastic materials as entirely new to the aircraft industry, but such is not the case. The primary difference between the materials used now is that they are now used in the applications where structural loads are involved, in the interiors, and in seats.

The use of thermoplastic in aerospace:

The thermoplastics are being used mostly for their transparent properties, mostly used in custom plastic parts or products, whether large or small, flexible or stiff, and any shape possible. Due to their high abrasion and chemical resistance, these can provide advantages for specific applications as compared to other solutions, particularly for the products used in aircraft. Customized thermoplastics tend to excel with greater durability when these are used in products that can experience wear and tear, for instance, in aerospace, interior design, or the air duct. The materials can vary in the performance they provide, these can generally provide higher toughness, lower mass, high-strength to weight ratio, and better surfaces out of the press.

These customizable and decorative plastics are used for interior applications, as mentioned in air ducts, cabin partitions, floor panels, and luggage bins. Another use is in structural applications including wing ribs and spars. Also, because of the benefits, plastics are now being used in the exterior of aircraft for things such as fuel tank covers. The reason this is being used is because of the excellent thermal stability provided at elevated temperatures.

Why plastic material for the Aerospace industry?

The advances in thermoplastic manufacturing and processing allow aircraft manufacturers and suppliers to take the advantage of the unique properties of thermoplastic material. One benefit of plastics that offer many advantages over other traditional aerospace materials is the manufacturing flexibility and efficiency it provides. Moreover, these can be recycled and also support environments and sustainability efforts which means the material can be molded and remolded into new forms if any mistake occurs in the process. These can be readily stored at room temperatures and have an unlimited shelf life which reduces and allows for more flexible production activities. When the useful life of thermoplastic ends, it can be potentially melted down to a product that requires less wear and tear.

The reason for a renewed emphasis on plastic is because of the many advantages it offers over aluminum and other traditional aerospace materials, such as being lightweight, with high strength and durability. With the use of thermoplastics, there is no change in the overall design of the existing machined parts; these can be easily tailor-made with a manufacturer having strong expertise and history in the aircraft interior industry.

Thermoplastic materials can outperform all other metals by providing thermal and mechanical stability as these are heat-resistant, non-corrosive and lightweight components with insulation properties, flame and chemical resistant. The use involves its multifaceted scope which is the main reason for its growth especially in the manufacturing of aerospace industry products. Among the trends and the multifaceted scope, there is continual improvement in the construction of aircraft materials. As more and more aspects of the vehicles are turning to hefty electronics for fuel efficiency, the lightweight, durability, stability, and decreasing the heaviness of the components is imperative for the aircraft.

What specific customization can be done to the thermoplastic material?

1- The very first step is to choose the textile, or finishing, though the pre-forming process remains the same. With the right partnering, can allow aircraft manufacturers to tailor the sheets, fiber, and shapes specifically for every component requirement.
 
2- The next step to take care of is the functionality, which is critical when customizing or choosing decorative plastic for the purpose. This calls for diligence, and only an experienced can add precise specific functions tailored to the requirements in aerospace.

Uses Of Thermoform Plastic Sheets

There are various forms of plastic available in the market. It is one of the most widely used materials in the business as you can mold and use it in different formats. The progress in the field of plastic material has made the process quite versatile. One of the widely used methods is the use of vacuum or thermoform plastic. It is a unique method that uses pressure and vacuum to build various forms used in automotive parts, medical parts, office equipment, and different other formats. One of the reasons why it is widely used across the manufacturing industry is the fact that it is affordable and dependable in every sense of the word.

OEM equipment covers: When you are on the lookout for material used in protection from ultraviolet radiation and corrosion, your best bet is the OEM equipment cover. It can be molded into the desired shape and can come in various colors as well. It is easy to brand and use it in different modes. Since the plastic sheet used vacuum forming for making the products, the whole process becomes easy and foolproof. Some of the common OEM materials used in the company are ABS (acrylonitrile butadiene styrene), HMWPE (high molecular weight polyethylene), AND ASA (acrylonitrile styrene acrylate).

Medical equipment covers: If you have ever seen a surgery room's insides, you will know and understand That there are various forms of medical equipment used in the process. They are high grade, and there is a need for precision in each item to ensure that the surgery is successful. These surgical items should be sterilized before and after use to ensure that they do not catch any infection. There is a high demand for covers of medical equipment. It should come in perfect shape to keep the whole part protected when not in use. Thermoformed medical equipment covers clean and dry medical instruments and equipment, including IV pumps, ventilators, and liquid oxygen system covers. This plastic sheet molding process is a reliable method of producing high-quality products needed for the medical industry. Acrylic, ABS (acrylonitrile butadiene styrene), PVC (Polyvinyl chloride), HIPS (High impact Polystyrene), HDPE (high-density Polyethylene) are the standard grades used for medical equipment and put through Thermoform plastic sheets.

Housings of CRT and plasma display: We see these products every waking hour of the day but have you ever imagined the make of these things? Consumer displays need housing to protect them from scratching the complex surface or getting dirt in them. Since they are mostly used in branded material in manufacturing houses, there is a dire need for thermoform plastic sheets. These materials are pressure formed to add logos, sharp corner guards, and detailed design as per the product designer. It is commonly used in PVC alloys, HIPS, and ABS. There is a high resistance of chemicals and stains, strength, rigidity, and flame-retardant qualities in the mentioned material, and that is why it is used in making these products.

Agricultural equipment: We all sit and enjoy the vegetables and meals made from various crops. There are a long process and hard work that goes into growing these things. Along with fertile land and good seeds, there is a need for Agricultural equipment to help the production work run smoothly. This agricultural equipment can be made up of TPO, ABS, PC, and Acrylic. They are primarily put to use for extreme resistance to impact, clarity, and sound insulation.

Tips On How To Find The Right Thermoplastic Company

Thermoplastic is becoming the material of choice for replacing traditional materials such as steel, aluminium and wood, among others. Compared to other traditional materials, thermoplastic has higher strength-to-weight ratios and offers great design flexibility.

If you are planning to replace or install or do any thermoplastic service but you don’t have expertise on how to do it, then you might consider taking the help of a thermoplastic company. Before finding the right thermoplastic, it’s always good to learn some vital information about different types of thermoplastic services offered by professional thermoplastic companies.

But before that, you also get advice and support from leading thermoplastic experts.

When it comes to choosing the right thermoplastic, it is important to compare the properties that each material has with requirements you have. The right thermoplastic companies are aware that the customers may not know a lot about thermoplastics but they won’t let that get in the way of making sure you invest in a product that fits your budget and requirements. Choose a company that has years of experience and highly in-depth knowledge and understanding of thermoplastics- and can provide you with expert advice you might require.

 

Understand how the material is made:

Thermoplastic is defined as a polymer made of binder, pigments, filler, and glass beads. The pigments used in it create the color, glass beads increase retroreflectivity, and filler adds bulk.

You might be thinking what makes the material of thermoplastic tough and flexible, the answer is binder, it helps in creating the bond strength to adhere to the pavement surface while holding the other components together.

Because of their unique properties, these thermoplastic materials can be remolded and recycled without causing any negative effect on the physical properties of the material. This property makes it an ideal material for injection molding.

From consumer goods to medical equipment, thermoplastic materials are used for a wide range of applications. The easiest to process are commodity thermoplastics which are used to manufacture products in high volumes. The commodity thermoplastic is best for applications like packaging, clothing, food and beverages. In contrast, engineered and specialized thermoplastic are used with it to enhance the properties of thermoplastic. These are used for heavier-duty applications like military, aerospace and medical industries.

 

Why is thermoplastic used in several different industries other than the traditional materials?

The only type of plastic which can be welded is thermoplastic. It can be molded into the desired shapes when the plastic is heated, the material becomes a paste or liquid like consistency. Each type of thermoplastic can withstand reshaping without any damage to the materials, but each type offers its own characteristics.

Types of thermoplastic:

• Polypropylene is used in a diverse range of products. The sheets are used for packaging and storage boxes and even stationery folders.
• Polystyrene is used in the manufacturing of plastic models of cars, in CD and DVD cases. This is available in various forms plus have differing applications, like product casing and manufacturing of toys.
• PVC or Polyvinyl Chloride is used by the construction industry for roofing sheets as it is a tough and lightweight material that has a high resistance to acids and bases.

 

Benefits of thermoplastic material:

• As discussed above these material can be molded and recycled without any damage
• These can be molded in any desired shape
• Lightweight with high strength and can be used in place of metal

Everything You Need to Know About Type 1 PVC

Polyvinyl chloride or PVC, an economical and versatile material is used in a variety of applications because of the properties it offers as a material. It is a commonly used thermoplastic in building and construction, automobile, healthcare and other sectors; offering excellent resistance to chemical and corrosion. This makes it a great choice for a wide range of materials ranging from piping, wire and cable insulation, plating of tanks and tubing and more.

What is Type 1 PVC?

Type 1 PVC is used in the application where the final installation is not subjected to high impacts. Though it is compatible to be used with materials that are chemical and corrosion resistance. These are very easy to fabricate and can be made available in both rods and sheets of various sizes and thickness according to the needs of customers.

Applications of type 1 PVC

This is potentially used in corrosive environments including:

●      Pool components

●      Laboratory equipment

●      Valves and fittings

●      Chemical processing equipment

Apart from these applications, it is used in the production of many products that you will encounter in daily life but are encountered less frequently in construction, healthcare and electronics because of its low cost and desirable physical and mechanical properties. Due to the flexibility it can be fabricated into a wide range of products that can be both rigid and flexible.

●   For wiring and cables: PVC is non-flammable and can resist exposures like changing of temperature and dampness. To simply put, it can withstand any tough conditions behind the building walls. For this reason, it is considered as one of the most trusted and prevalent materials that can be used in wiring and cables without any second thoughts. It can be also used as a coating for bare copper, aluminum and fiber-optic wires.

●   In Buildings for widows and sliders: As the material is highly durable and affordable, these are used in siding and window frames to help conserve energy when heating and cooling homes. As discussed it is strong and resistant to moisture and abrasion, PVC is ideally used in windows, fencing, roof and flooring. These don’t require much maintenance and frequent painting. These can be cleaned easily with a cloth and mild cleaning products.

●   Connecting pipes or water pipes: PVC pipes make strong, durable and non-reactive materials that can be used in water distribution, sanitary and underground piping applications. PVC has the properties to handle intense impact which means the pipes won’t break, rust or rot and prove to be a dependable material with affordability when it comes to choosing the best material for potable water-piping. It is recommended that you choose a PVC made pipe as it will help you conserve energy and water because of the leak free pipes that are not prone to corrosion and resist environmental stress.

●   Other uses:

It is ideal in clothing like rain coats, boots and shower curtains because of its affordability, durability and water resistance. Other uses include flexible packaging, carpet backing and resilient flooring.

Advantages of using PVC:

●   Good resistance to UV rays and weathering: Type 1 PVC is manufactured while keeping UV protection in mind, so these are made with UV stabilization for thermoforming applications and for general purposes.

●   Non-flammable: PVC is the most demanding thermoplastic material because of its resistance standards and due to its tendency of self-extinguishing.

●   Good stability: PVC can be rigid as industrial pipes, thin and flexible as much as you want or even pliable as plastic wraps. You can customize them to match clearly to any color you desire.

●   Tip: usually the grey plastic is used in industries and doesn’t have any protective masking. It is recommended that you choose a white PVC type 1 if you prefer to use it for displaying or sign posts.