Polyvinyl Chloride

Polyvinyl Chloride Thermoforming and Injection Molding

At Advanced Plastiform, Inc., we work with companies across the Southeast and Mid-Atlantic states, designing and manufacturing custom plastics for all types of use–-from car bumpers and trunk liners to medical trays and packaging. In order to provide the best outcome for each individual product, we have a wide variety of thermoplastic materials available to use, but one of the most common plastics we use is polyvinyl chloride, more commonly known as PVC. In fact, PVC is one of the most commonly used plastics in the world. 

What Is Polyvinyl Chloride?

Polyvinyl chloride is a thermoplastic polymer that can be heated and shaped for a multitude of materials. PVC in its pure state is highly rigid and brittle, but by adding plasticizers or phthalates, it can be softened, often taking the place of rubber, or blended with cotton to make canvas. 

PVC is highly durable and offers excellent resistance to chemical damage, water and moisture, and abrasion. Because it’s so versatile and can be blended with a variety of additives to change its properties from extremely rigid to soft and flexible, it’s commonly used in thermoforming, while its dimensional stability and low melting point makes it ideal for injection molding.  To learn more about PVC, please visit our frequently asked questions about Polyvinyl Chloride.

Polyvinyl Chloride Thermoforming

To create large plastic products and components, our engineering team often use polyvinyl chloride thermoforming, which involves heating the PVC material to where it is soft and flexible, then fitting it around a custom tool to create the ideal shape and design. 

Both affordable and efficient, our polyvinyl chloride manufacturing company uses three different types of PVC thermoforming methods to ensure the best results while providing lower costs and faster lead times to our customers.  

Vacuum Forming

Vacuum forming is the most basic method of polyvinyl chloride thermoforming in which the PVC is heated to a malleable state, then fitted to a custom tool. Then, a highly powered vacuum is fitted between the tool and plastic, removing all air from between the two and pulling it snugly against the tool, creating an accurate shape. This method is best for larger products where high levels of detail or sharply defined corners aren’t necessary. In fact, polyvinyl chloride vacuum forming is used for things like bathtubs and shower trays. 

Pressure Forming

For more intricate detailing and a less expensive alternative to polyvinyl chloride injection molding, we use pressure forming. Like vacuum forming, we fit heated PVC around a tool, but then, we use highly pressurized air to blast the plastic, pressing it firmly against the tool, creating sharp edges and corners and high levels of detail for construction materials and other products.

Twin-Sheet Forming

Polyvinyl chloride is most widely known for the rigid PVC pipe used in plumbing and water infrastructure systems. To create pipes and other hollow tubes such as air ducts, we use twin sheet forming. Twin sheet forming is the most complex polyvinyl chloride thermoforming method because it requires two sheets of plastic to be heated and shaped at the same time, then fitted and fused together. There is no room for error as the plastic must be matched precisely at pressed points in order to join together properly. 

Polyvinyl Chloride Injection Molding

For smaller plastic components and parts, or parts that require high levels of detail or varying thickness, we use polyvinyl chloride injection molding. This is a more intensive method of plastic manufacturing because it requires designing a double-sided mold made from steel, aluminum, or copper alloy. Then, the PVC is melted to a liquid state and injected into the mold, creating a detailed, highly accurate finished shape that is either ready for painting or customization or to be packaged and sent to our customers. 

Kydex: The Aero-Grade Material for Advanced Applications

Kydex is a high-performance, thermoformable plastic that represents 90% of the PVC products manufactured at Advanced Plastiform, Inc. Renowned for its strength, durability, and flame retardant properties, this aero-grade material is essential for critical applications where safety and reliability are paramount.

Aerospace Applications

In the aerospace industry, Kydex is indispensable. Its inherent flame retardancy meets the strict safety requirements for all thermoformed plastics used on aircraft, ensuring that every component contributes to the overall safety and performance of the craft.

Automotive Components

Kydex is used for custom interior panels, dashboards, and protective coverings. Its resistance to impact and chemicals, along with its flame retardant properties, ensures that components not only look sleek but also meet safety standards in automotive environments.

Medical Devices and Equipment

Its chemical stability and ability to be precisely molded allow Kydex to be used in manufacturing medical trays, enclosures for diagnostic equipment, and other components that require a sterile, durable material that withstands rigorous cleaning protocols.

Industrial and Electronic Enclosures

Kydex offers excellent impact resistance and can be formed into complex shapes, making it ideal for protective housings in industrial equipment or enclosures for electronics that need to resist harsh environments.

Custom Gun Holsters and Other Consumer Products

Kydex is the material of choice for gun enthusiasts and preppers. Its ability to be precisely thermoformed allows for the creation of custom gun holsters that are not only durable but also designed for secure, everyday carry—meeting the practical demands of personal defense.

From protective cases to bespoke equipment panels, Kydex’s ability to be customized to exact specifications is highly valued in the design of high-end consumer products, where both aesthetics and functionality are paramount.

Other PVC Applications

Both rigid PVC and flexible PVC have a wide variety of uses. While most people equate it with PVC pipe and other construction materials, it’s also the plastic used in vinyl siding, window frames, and roof lining. 

In fact, it’s used in virtually every industry to make things like:  

• Shower curtains
• Packaging, including bottles, blister packs, and shrink wrap
• Garden hoses
• Cable and wire insulation
• Flooring and wall coverings
• Medical tubing and IV bags
• Rain coats and rain boots

Contact Advanced Plastiform for Polyvinyl Chloride Manufacturing

We’re proud to be a leader in polyvinyl chloride manufacturing, known for providing competitive pricing and fast lead times. We work with a variety of industries, creating reliable, long-lasting plastics for businesses in North Carolina, South Carolina, Pennsylvania, Maryland, Tennessee, Georgia, and Virginia. 

Please contact us today by calling  919-404-2080 or filling out our east-to-use online contact form to discuss your custom plastic manufacturing needs.