Twin Sheet Thermoforming Services

custom plastic parts

Twin sheet thermoforming is a manufacturing process used to produce highly customized plastic parts and products. During processing, two or more thermoplastic sheets are heated and shaped into the desired final product by placing them in a mold and applying thermal pressure. Typically, twin sheet thermoforming service is suitable for projects that require a high degree of customization, low-volume or medium-volume production, as it provides the unique flexibility to accommodate a variety of shapes, sizes and design requirements. The twin sheet thermoforming process is an excellent choice for industries such as automotive manufacturing, electronic equipment, and consumer goods.

Twin Sheet Thermoforming

What Is Twin Sheet Thermoforming?

Twin sheet thermoforming is a manufacturing process used to create hollow plastic parts or products by simultaneously forming two separate sheets of plastic material into a single three-dimensional structure. In this process, two sheets of thermoplastic material are heated to a pliable state and then positioned in a mold with two cavities, one for each sheet. The mold cavities are designed to define the shape of the final product.

Once the sheets are in place, a vacuum is often applied to help conform the plastic to the mold’s shape. Heat and pressure may also be used to ensure proper molding and bonding of the two sheets together. The result is a hollow, double-walled structure with a sealed perimeter, creating a wide range of products such as containers, enclosures, automotive parts, and more.

Surface finish plays a critical role in thermoforming, whether the product is painted or unpainted. Undesirable surface inconsistencies, often referred to as “shadowing,” can occur along the sides near the juncture of the twin sheets. To mitigate shadowing, a technique known as bead-blasting can be employed on the mold, providing the panel with a textured finish and improving surface uniformity.

Twin sheet thermoforming is chosen for its ability to produce durable, hollow parts with varying wall thicknesses and complex geometries. This process is particularly advantageous when strength, insulation, or aesthetics are essential for the final product. Additionally, it allows for the integration of features like undercuts, inserts, and internal structures within the part.

Advantages of Twin Sheet Thermoforming

Twin sheet thermoforming offers a range of benefits, making it a versatile and valuable manufacturing process. Some key advantages include:

    • Two-Color and Custom Color Layering:
      This process allows for the creation of products with two-color options and the ability to layer custom colors, enhancing aesthetic appeal.
    • Integration of Separate Components:
      Twin-sheet forming enables the formation of hollow products with separate components inside, offering versatility in design and functionality.
    • Internal Reinforcements:
      It allows for the incorporation of internal reinforcements like rigid foam components, increasing structural strength and durability.
    • Enhanced Structural Stability:
      Products manufactured through twin-sheet thermoforming exhibit improved structural stability, crucial for applications requiring robustness.
    • Molded-In Attachments:
      The process can seamlessly integrate molded-in attachments, simplifying assembly and enhancing product functionality.
    • Variable Sizes:
      With a size capability ranging from 8″ x 8″ to 7′ x 11′, twin-sheet thermoforming accommodates a wide range of product dimensions.
    • Air and Wiring Ducts:
      It permits the inclusion of air and wiring ducts within the product design, facilitating ventilation and cable management.
    • Texture and Wall Size Variability:
      Multiple textures and variable wall sizes can be achieved, allowing for diverse design possibilities.
    • Lightweight and Heavy-Duty Products:
      Twin sheet thermoforming creates products that are lightweight yet heavy-duty, ideal for applications requiring durability and a lightweight design.
    • Cost-Effective Production:
      The process is cost-effective for producing complex, multi-layered products, reducing manufacturing costs and increasing efficiency.

Twin sheet thermoforming is particularly well-suited for the creation of heavy-duty industrial parts with exceptional strength, rigidity, and stiffness. These parts combine lightweight properties with durability, making them ideal for applications that demand robustness, structural integrity, and minimal weight.

Materials for Twin Sheet Thermoforming

Twin sheet thermoforming relies on a variety of thermoplastic materials, each chosen for its unique properties and suitability for diverse applications. It allows the utilization of a variety of materials to achieve the desired properties of the final product, making it an adaptable and versatile manufacturing process. Here are some common materials utilized in twin sheet thermoforming:

    • Thermoplastic Polyolefins (TPO):
      TPO materials exhibit high impact resistance and maintain excellent performance in both extreme cold and high-temperature environments. They are frequently chosen for their durability and adaptability in a wide range of applications.
    • Acrylonitrile Butadiene Styrene (ABS):
      ABS is a versatile thermoplastic renowned for its exceptional impact resistance and resistance to chemicals. It is extensively used across various products, including automotive components, consumer goods, and electronics.
    • High-Density Polyethylene Sheets (HDPE):
      HDPE sheets are prized for their remarkable impact strength, making them a preferred choice for industrial products and applications where durability is paramount. They are also known for their resistance to chemicals and corrosion.
    • High Impact Polystyrene (HIPS):
      HIPS is lightweight, cost-effective, and offers good impact resistance. It is commonly employed in food packaging, housing applications, and products where a balance of affordability and performance is required.
    • Acrylic:
      Acrylic materials are celebrated for their outstanding shatter resistance, weather resistance, resilience, and flexibility. They are often used in applications where optical clarity, impact resistance, and durability are crucial, such as protective shields and transparent enclosures.

Twin Sheet Thermoforming Services–Sungplastic

Twin sheet thermoforming is a specialized manufacturing process designed to create plastic parts and products with complex structures and customization requirements. This process allows for the realization of multi-layer structures in a single process, providing greater freedom in design and more functional options.

Sungplastic is an experienced thermoforming company, we have a professional team of engineers, advanced technical equipment, and a wide range of material selections to ensure that the quality and performance of the final product reaches the expected level. Our technical staff will select appropriate thermoplastic materials and processing techniques based on your project needs to meet your individual needs.

If you are looking for an excellent thermoforming manufacturer, Sungplastic is your best choice. We are committed to providing high quality twin sheet thermoforming and injection molding services to meet the needs of a variety of industries and applications.

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