Why You Should Choose Twin Sheet Thermoforming

Reasons to Choose Twin Sheet Thermoforming for Plastic Manufacturing

When you need plastic tubing, hollow panels over housing or enclosures for trash chutes, air ducts, and truck components, twin sheet thermoforming is often the best option for producing the durable products you need. Often used as an alternative to blow molding, to help you better understand its advantages, our North Carolina thermoforming company is taking a closer look at twin sheet thermoforming.

Understanding Twin Sheet Thermoforming

Twin sheet thermoforming is a complex method of plastic forming in which two sheets of plastic are heated to a malleable state at the same time, then they are clamped to the tooling and drawn tightly against the mold to achieve the desired shape. After the two sheets are shaped, they are carefully fused together to create a seamless unit, allowing us to easily construct double-walled pieces and panels or hollow products efficiently and precisely.

Vacuum Twin Sheet Thermoforming

Vacuum thermoforming is a method of forming in which the two sheets are clamped to the mold, then strong vacuums underneath the plastic suction out any air between the mold and the plastic. This draws it tightly to create curves and sections for cuts.

Pressure Twin Sheet Thermoforming

Pressure thermoforming is similar to vacuum molding, except in addition to the vacuum, a jet of pressurized air is blasted onto the plastic to press it more firmly against the mold. This is often used to get tighter corners and angles.

Advantages of Twin Sheet Thermoforming

Now that you have a better understanding of how twin-sheet thermoforming works, let’s dive into why this method is an excellent choice for your next project.

Lower Tooling Costs

Twin-sheet thermoforming offers significantly lower tooling costs compared to injection molding. This makes it an ideal solution for projects requiring high-quality results without the hefty upfront costs associated with more complex manufacturing processes.

Customization Options

With twin-sheet thermoforming, you can enjoy greater customization capabilities. This includes the option for two-color products or varying material thicknesses within a single piece, which is something not achievable with blow molding. Whether you need a specific design or unique functionality, twin-sheet thermoforming can accommodate your needs.

Versatile Textures and Hinges

The process allows for multiple textures and even hinge capabilities, offering more flexibility in design and functionality. This can be particularly beneficial for applications requiring intricate or highly functional components.

Faster Lead Times

Due to the ease of tooling fabrication and the fact that twin-sheet thermoforming uses a single process rather than multiple steps, lead times are much faster. There's no need to vacuum form each side separately and then glue or fuse the parts together, saving both time and cost.

Hollow or Double-Walled Parts

Twin-sheet thermoforming excels at producing hollow or double-walled pieces, which is a key benefit for products that require additional strength or insulation without the weight and cost of solid materials. 

Easy Tooling Modifications

If you need to modify the tooling for different product configurations, twin-sheet thermoforming makes it simple and cost-effective. This flexibility allows for changes in design without extensive downtime or cost increases.

Compatibility with a Wide Range of Thermoplastics

All types of thermoplastics can be used in twin-sheet thermoforming, including heavy-duty materials like ABS, PVC, and acrylic. This means you can select the best material for your project based on its specific requirements, such as strength, flexibility, or heat resistance.

Extensive Finishing Options

Twin-sheet thermoforming offers nearly unlimited finishing options, including paint, stenciling, or various coatings. This versatility allows for a customized, professional appearance that suits the end product’s needs.

Common Uses for Twin Sheet Thermoforming

Twin sheet thermoforming is most often used for air ducts and trash chutes - large, hollow tubes. However, it's also used to make the following items:

• Vending machine inserts
• Plumbing pipes
• Bed liners
• Drain pipe extenders

Twin sheet thermoforming is also ideal for any hollow or double-wall items that need small to medium product runs as this is typically the most cost effective option.

Get a Free Quote for Custom Manufactured Plastics

If you would like to discuss twin sheet thermoforming, reach out to our team at Advanced Plastiform, Inc. today. We work with companies throughout the Mid-Atlantic and Southeastern states including North Carolina, South Carolina, Pennsylvania, Maryland,   Tennessee, Georgia, and Virginia.

To learn more about our services or get a free quote, contact us today. Get started by calling us at  919-404-2080 or filling out the form below.