Thin Gauge vs Heavy Gauge Thermoforming

What is Thin Gauge vs Heavy Gauge Thermoforming?

In simple terms, thin gauge thermoforming involves heating a thin sheet of plastic until it becomes pliable and is typically used for packaging and disposable items. Heavy gauge thermoforming instead uses thicker sheets of plastic to create durable products like automotive components and electronic enclosures. However, there is much more complexity to the differences between these two manufacturing processes beyond the gauge of materials used.Join our North Carolina thermoforming company as we take a closer look at both thin gauge thermoforming and thick gauge thermoforming to help you determine the right method for your next project.

Techniques for Thermoforming Plastic Components

Thermoforming is a manufacturing process where a plastic sheet is heated until it becomes pliable, then shaped into a specific form using a mold. This process is widely used to create a variety of products, from packaging and disposable items to automotive components and medical devices.

Vacuum Forming

In vacuum forming, a heated sheet of thermoplastic is draped over a mold, and a vacuum is applied between the mold and the sheet to draw it tightly against the mold's contours. This method is commonly used for packaging, trays, and shallow parts.

Pressure Forming

Pressure forming is similar to vacuum forming but involves using additional pressure, either from the top or bottom of the mold, to force the heated plastic sheet into intricate details and deeper molds. This results in parts with enhanced definition and strength, suitable for more complex shapes and thicker materials.

Twin Sheet Forming

Twin sheet forming involves simultaneously thermoforming two separate sheets of plastic, then bonding them together to form a hollow, double-walled structure. This method is used for applications requiring durability, insulation, or fluid containment, such as automotive components and industrial containers.

Thermoforming vs Injection Molding

Thermoforming heats a plastic sheet to form it over a mold, making it suitable for low to medium production volumes of simple shaped plastic parts. Injection molding, on the other hand, injects molten plastic into a mold under high pressure, offering high precision and versatility for complex parts in large volumes.

What is Thin Gauge Thermoforming?

Thin gauge thermoforming, also known as light gauge, refers to the thickness of the plastic being used. For the plastic sheet to be considered thin gauge, it will be less than 0.06 inches or 1.5 millimeters thick. Often, the light gauge plastic sheet is kept on a roll with the roll fed through the thermoforming machine, where it is fitted, formed, and then trimmed in rapid succession.

Because the thermoplastic material is so thin, it makes for highly visible, detailed final results. This may include logos or textures pressed easily into the form, making for a custom made plastic product with highly visible or ornate details.

Light Gauge Thermoforming Process

Light gauge thermoforming begins by heating a thin sheet of thermoplastic material and then transferring the plastic sheet to a mold where it is shaped using either vacuum pressure or positive pressure to conform to the mold's contours.

Once formed, the plastic part undergoes cooling to solidify its shape, followed by trimming to remove excess material and achieve precise dimensions. Additional finishing processes like heat sealing, painting, or assembly may be applied to enhance the functionality or aesthetics of the thermoformed part.

This process is efficient for producing thin-walled products like packaging trays and disposable containers due to its versatility in material selection and cost-effectiveness in medium to high volume production.

Types of Plastic Used in Thin Gauge Thermoforming

Plastics typically used in thin-gauge thermoforming include:

Industries Using Thin Gauge Thermoforming Methods

Thin gauge thermoforming methods are employed across various industries due to their versatility, cost-effectiveness, and ability to produce lightweight yet durable products.

Some of the key industries utilizing thin gauge thermoforming include:

Packaging: Thin gauge thermoforming is extensively used in the packaging industry for creating shipping trays, clamshell packaging, blister packs, and durable containers for food packaging, pharmaceuticals, electronics, and consumer goods. These products offer protection, visibility, and ease of handling during transportation and display.
Food Service: The food service industry relies on thin gauge thermoforming for manufacturing disposable cups, plates, bowls, and food containers. These products are lightweight, hygienic, and often feature custom designs or branding for retail and takeaway applications.
Medical and Healthcare: Thermoformed products play a critical role in the medical and healthcare sectors, producing items such as surgical instrument trays, blister packs for medications, and disposable medical device parts. These products meet strict cleanliness standards and provide reliable performance in clinical environments.
Consumer Goods: Various consumer goods industries utilize thin gauge thermoforming for producing items such as cosmetic packaging, storage containers, toys, and household products.

Thin gauged thermoformed products offer durability, aesthetic customization, and cost-effective production capabilities.

What is Heavy Gauge Thermoforming?

Heavy-gauge thermoforming relies on thicker plastic sheeting up to 0.45 inches or 11 millimeters thick. Instead of a roll, the plastic comes in individual sheets as large as eight feet long and nine feet wide. The plastic is heated, laid over the mold and clamped in place, then the vacuum pulls it against the mold. In order to get sharper details and corners, pressure forming may be used, in which pressurized air presses down onto the plastic, forming it more tightly to the mold.

Process of Creating Heavy Gauge Thermoformed Parts

The process of creating heavy gauge thermoformed parts begins with heating a thick sheet of thermoplastic material until it becomes pliable. The heated sheet is then transferred to a robust mold, often made from aluminum, where it is shaped using vacuum pressure and mechanical assistance to achieve intricate contours and deep draws.

After forming, the part undergoes controlled cooling to ensure dimensional stability. Excess material is trimmed away using CNC machines, and additional finishing operations may be applied as needed. Throughout the process, rigorous quality control measures, including dimensional checks and material thickness verification, are implemented to ensure the parts meet precise specifications and performance requirements.

This process is essential for producing durable plastic components used in automotive, industrial, and other heavy-duty applications.

Types of Plastic Used in Heavy Gauge Thermoforming

Common thermoplastic materials used in heavy-gauge thermoforming includes:

Acrylonitrile Butadiene Styrene (ABS)
High-impact polystyrene (HIPS)
Polycarbonate
High-density polyethylene (HDPE)
Polyvinyl chloride (PVC)
Thermoplastic olefin (TPO)

Industries That Rely on Heavy Gauge Thermoforming

Several industries rely on heavy gauge thermoforming for producing thicker packaging and sturdier components.

Some of these key sectors include:

Automotive: Heavy gauge thermoforming is integral to manufacturing automotive components such as truck bed liners, vehicle panels, interior trim, and structural parts. The process provides lightweight, impact-resistant solutions that meet stringent performance and safety standards.
Industrial Equipment: Industries producing heavy machinery and equipment, such as construction and agriculture, utilize thermoformed parts for large-scale enclosures, protective covers, and structural components. These parts offer durability, corrosion resistance, and thermal insulation properties.
Aerospace: Aerospace manufacturers employ heavy gauge thermoforming for creating interior components, cockpit panels, and protective covers due to the material's lightweight characteristics and ability to meet aerospace-grade specifications.
Electronics and Telecommunications: Heavy gauge thermoformed enclosures and housings are used to protect electronic equipment and telecommunications infrastructure. These thermoformed parts offer durable shielding against environmental elements, ensuring reliable operation and longevity in diverse operational settings.

Heavy gauge thermoforming enables these industries to achieve cost-effective production of large, complex parts with design flexibility and reduced tooling costs compared to traditional manufacturing methods like injection molding.

How to Choose Thin Gauge vs Heavy Gauge Thermoforming for Your Projects

Understanding thermoforming needs helps to make the critical decision of choosing between thin gauge vs heavy gauge part thickness for your projects.

Lower Tooling Costs

Thinner materials generally incur lower tooling costs due to their ease of molding and shaping, requiring less robust equipment. This cost-effectiveness makes thin gauge thermoforming ideal for projects prioritizing initial investment savings.

More Durable Containers

Heavy gauge materials excel in durability and strength, crucial for applications needing robust protection against mechanical stress and impacts. They ensure containers maintain integrity through rigorous handling and extended use, making heavy gauge thermoforming suitable for demanding environments.

Better Design Flexibility

Thin gauge materials offer flexibility for intricate and detailed designs, ideal for projects requiring complex shapes or precise specifications. Conversely, heavy gauge thermoforming provides flexibility for larger, structurally demanding products, balancing durability with design intricacies.

Large Quantities

When large quantities of uniform containers are needed, heavy gauge thermoforming is often preferred due to its durability and consistency in maintaining product integrity. It can handle the demands of producing large quantities without compromising on structural stability or quality.

Prototyping

Thin gauge thermoforming is well-suited for product prototyping due to its lower tooling costs and flexibility in design changes. It allows for adjustments in the initial stages of product development, facilitating cost-effective testing and refinement before moving to full-scale production.

Contact Advanced Plastiform for a Free Quote for Thermoforming Custom Plastics

When you need a thermoforming company to produce high-quality, durable plastics with a fast turnaround time and a low per-unit price, reach out to Advanced Plastiform, Inc. We work with a wide variety of industries across the Mid-Atlantic and Southeast, including North Carolina, South Carolina, Pennsylvania, Maryland, Tennessee, Georgia, and Virginia.

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