Thermoforming
describes the process of moulding plastics to its softening point and
stretching it over or into a single-sided mold and solidifying it into the
desired shape to create a variety of usable products. Thermoforming differs
from injection molding, rational molding or other forms of processing plastics.
Thermoformingplastics are commonly used for food packaging, but have many applications other
than that, including in plastic toys to aircraft windscreens. Thin gauge is
usually less than 0.060 inches, and is used for rigid or disposable packaging
like manufacturing of disposable cups, containers, lids, blisters and other
products for food, medical or retail industries. Thick gauges usually greater
than 0.120 inches are typically used in parts as diverse as vehicle doors and
glass panels, refrigerator liners, aircraft windscreens or electrical
equipment. Before we discuss the plastic materials used in thermoforming, let’s
have a look at several factors that go into the selection of the best material for
your required applications. Some of the common factors include:
- Stiffness or rigidity, consider how stiff the final product needs to be or it will have some flexibility in order to fulfil its intended use?
- Impact strength- how strong the final product needs to be in order to withstand any cracking, abrasion or chipping that may come along with the usage of it?
- Finishing and customizing options- does the manufacturer provide you with the desired color and if the surface can be customized according to color of your choice? Will it have different textures and graphics on the part?
- Cost- cost will totally depend on the quality of the material. Considering whether you will require the least expensive part or quality is more important to you.
- Is appearance a more important factor as compared to strength or both come along for you?
- It is also important to consider the other material that will come in contact with the part. So compatibility is important.
- How much heat the final plastic product will be able to withstand before it begins to distort?
Below are
some of the most common plastics used in thermoforming along with their basic
characteristics:
HDPE Plastic:
HDPE or
high-density polyethylene is a stronger thermoformed plastic that is known for
its exceptional strength to density ratio. It is a petroleum based
thermoplastic polymer used in various applications such as bottles, plastic
packaging and plastic bags. It is considered a great choice for products like
shampoos, trays and recycle bins.
● Lightweight
● UV resistant
● Chemical and corrosion resistant
● Excellent impact resistance
ABS:
ABS is known
for its tough resilience to elements like heat. It can withstand temperatures
ranging anywhere from -4 to 176° F. This makes it an ideal polymer for products like automobile parts,
headgears and kitchen appliances.
●
Used in interior/exterior components.
●
In seats
●
Good strength and stiffness
●
Functional in all temperatures
HIPS:
High impact polystyrene is a versatile plastic that
is used in a variety of products as it can be molded into different shapes
multiple times and still preserve its properties. It can be customized in
different colors and the low cost of this material makes it a popular option.
●
Available in many colors
●
Lower costs
●
Responds well to paint
●
Excellent impact resistance
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