A Simple Guide to Thermoforming Plastics

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

Custom Textures In Thermoplastic Sheets

With a great variety of plastics available today there comes many different applications as well. The demand of plastic has taken over other materials largely due to the fact that plastic is much easier to process and therefore a lot less expensive. Thermoplastics are one of the popular and common plastics as their unique properties allow them to be used in a variety of different applications with a variety of custom textures. 

These sheets are used to manufacture many everyday products. It is used for commercial and personal use because of the fact that it is more lightweight, durable and cost-effective than any material. With time it has become a preferred material of choice by many enterprises seeking products such as table top protectors, for furniture and shelves. 

If you are confused when searching online, expert consultants are always there to give you advice and information you need to make the right decision.

Getting custom textures can be an integral component of your project and offers a potential enhancement in design, branding, aesthetics and functionality of the product. Thermoplastic sheets are available in a huge array of looks and feels that are due to the surface structure or texture of those parts. Custom textures or Texturing also referred to as graining or engraving- is the process of adding a pattern also said as the texture or grain to the surface of the sheet. 

Compared to getting leather or wooden material, texturing or graining of a thermoplastic sheet is a very economical way to impress complex designs or patterns on molded plastic parts. 

Apart from being economical, these are highly chemical resistant and can be easily cleaned with any common household cleaners. The texture of the thermoplastic sheet also plays a major role in the ease of cleaning. A shallow textured sheet can easily be cleaned with a soft cloth, while if a sheet has a heavier texture it may require use of heavy hand and rigorous material to remove dust from the surface. 

How can getting a custom texture enhance a product's design, look and brand?

Visual appearance and textures in a design have been used from years by many brands to convey a variety of messages and emotional responses. Having a decent finish to a product with an elegant texture can give an idea of class with smooth, high gloss or matte finishes, or strength and industrial responses from rough or hard finishes. These textures are meant to give the illusion of having a real, physical texture, such as leather, wood grain, technical texture, canvas, fabric and what not.

Just as people react to colors, tints and shades, they also react equally to textures. So before making any decision just remember that every texture has its corresponding trait that you must consider before finalizing it for your brand. Try resonating the image your brand is willing to express and go ahead with what feels like it.

What are the benefits of getting a custom made sheet?

● Highly aesthetic

● More resistance to scratches

● Durable, lightweight and shatter-resistance

● Economical than any other material

● Maintains its finish

● Easy to maintain and clean

How Airplane Plastics are Changing the Aerospace Industry?

Aluminum, steel and titanium used to reign supreme in the world of aerospace manufacturing, taking up 70% of the average aircraft. Yet as demands for weight reduction and fuel efficiency increase, metals are losing ground to the new kid in the game- thermoplastic polymers and composites. You need to only consider the latest generation of modern aircraft to see the impact these materials are having on aerospace manufacturing.

In airplanes, plastic is typically used for interior applications, such as air ducts, cabin partitions, floor panels and overhead luggage bins. It’s also used for avionics sensor plates, electronic component mounting brackets and ventilation impeller blades.

Structural applications include wing ribs and spars. In addition, plastic is used on the exterior of aircraft for things such as fuel tank covers, landing gear hubcaps, pylon fairings and radomes.

But what is the reason behind this drastic shift from aluminium and steel to thermoplastics like PEEK, PPSU, PEI, and other polymer materials? As it turns out, there is more than one explanation.

Plastic offers many advantages over aluminum and other traditional aerospace materials, such as light weight, high strength and durability.

Weight reduction is one of the greatest advantages of composite material usage. A lower-weight plane is more fuel-efficient because it requires less fuel to propel itself forward. Polymer and composite materials meet the challenge of helping reduce aircraft weight by being up to ten times lighter than metal. This sharply lowers lifetime fuel costs, reduces emissions, and extends the flight range.

Composites are also incredibly strong and as a result have a higher strength-to-weight ratio, also known as specific strength, than the metals used in making aircraft. In addition, they resist compression and don’t easily break under tension. Airplane plastics are not prone to corrosion due to harsh chemicals, and they are resistant to many highly reactive chemicals. They can also handle wide variations in temperature and exposure to severe weather.

Another big advantage of composites is their design flexibility: they can be made into just about any shape. And a single, oddly shaped piece of composite can replace many pieces made of other materials. That helpful characteristic cuts down on maintenance and so can reduce costs over the lifetime of a plane. Once a composite piece has been formed, it maintains its shape and size. That is important in the aircraft industry because it means the essential parts of a plane made out of composite materials won’t grow, shrink or change form as environmental conditions vary.

In addition, the use of plastic composites in airplanes reduces the scrap and waste produced from working with traditional materials. And plastic composites also are less susceptible to fatigue and corrosion, so the aircraft lasts longer and requires only a few repairs.

The use of composite materials might even make for more comfortable travel. Why? The composite materials used in airplanes can sustain lower cabin pressure at high altitudes and higher humidity levels than traditional aluminum- bodied planes, so it is expected that passengers will fly more comfortably and arrive in their destinations feeling more rested.