Plastic Storage Trays & Custom Thermoforming Solutions

Plastic Manufacturing and Thermoforming: Common Questions

What is thermoforming?

Thermoforming is a plastic manufacturing process in which a thermoplastic sheet is heated until pliable and then formed against a mold. It produces everything from thin packaging to heavy structural components, and is one of the common alternatives to injection molding for larger parts at low to moderate volumes.

What is the difference between thermoforming and injection molding?

Thermoform tooling is typically single-sided and less expensive to build than a matched injection mold, so the fixed tooling cost spread across a program stays lower. Injection molding generally becomes more economical at very high volumes and for smaller parts with thick or intricate geometry.

What is the difference between heavy gauge and thin gauge thermoforming?

Thin gauge thermoforming feeds material continuously from a roll and is typical of packaging. Heavy gauge thermoforming forms pre-cut sheet one part at a time, and is the approach used for enclosures, covers, guards, panels, trays and reusable containers.

Is vacuum forming the same as thermoforming?

Vacuum forming is one method within thermoforming. Thermoforming is the umbrella term for heating and shaping a plastic sheet; vacuum forming achieves that shaping by evacuating the air between the sheet and the mold so atmospheric pressure presses the material into place.

What plastic products are commonly thermoformed?

Common thermoformed products include storage and organizational trays, food handling totes and lugs, material handling containers, reusable shipping and dunnage packaging, and OEM components such as covers, enclosures, shrouds, bezels and guards.

What should a buyer send to get a custom plastic part quoted?

A useful quote package generally includes the part's purpose, approximate dimensions or a CAD file, expected annual volume, target timeline, any material preference, and whether tooling already exists, sits with another supplier, or has yet to be built.

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