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214. Thermoforming

Thermoforming creates shapes from a thermoplastic sheet that has been heated to its softening point. Applied vacuum or pressure draws or pushes the softened sheet over an open mold or form where it is then cooled to the conforming shape. The process of stretching the sheet over the form or mold causes thinning of the wall, especially along the sides of deep-drawn features. Mold or form costs for this low-pressure process are much lower than for plastic molds of comparable size.

Thermoforming can produce large parts on relatively inexpensive molds and equipment. Because the plastic is purchased as sheet stock, materials tend to be costly. Material selection is limited to extrusion grades. Secondary operations can play a large role in part cost. Thermoformed parts usually need to be trimmed to remove excess sheet at the part periphery. This process cannot produce features that project from the part surface such as ribs and bosses. Cutouts and holes require secondary machining operations.