Thermoforming and Plastics Used in Product Manufacturing

Thermoforming is a simple process that involves heating suitable thermo-formable plastic sheets to their 'forming' temperature, and subsequently shaping them into desirable shapes by applying force. This can be done through various methods including using mechanical assist plugs, vacuum and form air. Plastic sheets manufactured through 'extrusion' are the most used raw material in the process of Thermoforming, due to higher flexibility and control during the process. Once the material reaches the optimal forming temperature, it's transported to the forming station and the mold is closed upon the pliable sheet for it to attain the desirable shape.

Thermoforming has limitless applications in the current world, with the ever-increasing need for re-usable plastic materials. From thermoform disposables to medical- packaging, these materials come in handy due to their lightweight and convenient availability.  

Common uses of Thermoform Plastics 

●     Retail clam shell packaging

●     Packaging blisters

●     Pick and place trays

●     Material and handling tray and cover

●     Shipping trays

●     Medical packaging

●     Pop displays

●     Packaging inserts

 Brief view into the popular Thermoformable plastic sheets used- 

ABS Plastic (Acrylonitrile Butadiene Styrene)- Due to its tough and dependable resistance to elements like heat, this thermoformable plastic sheet can be easily molded at high temperatures. It's commonly used for mechanical purposes like plumbing, and can also be employed in making protective headgear, golf club heads, musical instruments like recorders, and for toys like LEGOs. This plastic can also be used in several tattoo inks. 
HIPS Plastic (High-Impact Polystyrene)- It can be used for foamed or rigid plastic. It is quite cost-efficient and is available in various colors. This plastic forms very easily making it a popular choice for thermoforming processes. As compared to ABS, HIPS plastic is clearer and brittle.  Hips plastic sheets are used for forming materials for protective packaging for food and drink items, clam shell containers, disposable cutlery and bottles. 
HDPE Plastic (High-Density Polyethylene)- This thermoformable plastic is a stronger version of HIPS Plastic and is comprised of petroleum. Due to its exceptional strength and high density, this plastic can be used for diverse applications, including making plastic bags, hula loops and even fireworks, water-pipes and cable-installation.
PVC Plastic (Polyvinyl Chloride)- This is the third-most used plastic in thermoforming processes. The manufacturing process consists of 'suspension polymerization', giving this plastic a strong, rigid and hard structure. This rigidity gives this plastic the ability to with- stand high temperatures and pressures. It costs less, making it a lucrative option. It can be efficiently used in manufacturing sewage pipes, commercial signage, electric cables, flooring, faux leather clothing etc.
PET Plastic (Polyethylene Terephthalate)- This clear and low-cost plastic is one of the most used thermoformable plastics. The most common use of this plastic can be seen in food-packaging and bottle production, as its FDA approved and hence safe to use. It is also used in synthetic fiber production. PET plastics have a great resistance to external elements as they are dried after being thermoformed and molded. The most appealing feature of PET plastics in our world where plastic accumulation is one of the largest concerns, is their great ability to be easily recycled. This makes them a profitable, yet eco-friendly option. 
PETG Plastic (Polyethylene Terephthalate Glycol)- PETG plastics are a variation of PET plastic. These are used for blister-packaging and in making trays. Just like PET this material is clear and has great impact strength.

In addition to the above mentioned thermoformable plastics, various other options are available, with an equal quantity and quality of resourcefulness and utility. These include plastic sheets made from Acrylic, LEXAN, Pennate, Royalties, Vinyl among various others. Their different properties make them eligible for different applications and although there can be various drawbacks, it cannot be denied that our daily life can get dangerously impacted in their absence. The need of the hour is not to get rid of plastic- consumption, but to legislate and execute an impactful strategy of reduce, reuse and recycle. This will help us improve our standards of living, while taking care not to hamper the processes of environmental sustainability and stability.