Thermoforming is a versatile and cost-effective manufacturing method to create plastic parts and products. One key consideration in the process is choosing between heavy gauge and light gauge materials, which refer to the plastic sheet’s thickness. Both options have distinct benefits, contingent upon the specific project application and requirements. In this blog article, we will examine the distinctions between heavy and light gauge thermoforming. We will particularly explore their advantages and applications for which each is ideal. Heavy Gauge Thermoforming Heavy gauge thermoforming is a manufacturing process that involves heating a thick thermoplastic sheet until it becomes pliable. The sheet often ranges from 0.050” to 0.75” in thickness and can be made of various materials, including polycarbonate and acrylic. The process starts with a flat sheet of thermoplastic material loaded into a heating chamber and heated until it becomes soft. The softened sheet is then placed onto a mold or tool, which applies vacuum and/or pressure to form the plastic into the desired shape. Once the plastic has cooled and solidified, it is removed from the mold and trimmed to the final structure. Advantages Here are several benefits of utilizing heavy gauge thermoforming: Ability to produce less waste compared to injection molding or machining Capacity to make large, durable, and intricately shaped components Capacity to work with a variety of materials, such as high-temperature polymers and reinforced composites Ability to generate intricate geometry and detailed drawings Personalized surface finishes and hues Superior durability and impact resistance Comparatively low tooling costs to other manufacturing processes Applications Heavy gauge thermoforming is a versatile manufacturing process used in various applications across many industries. Its ability to produce large, complex, and durable parts with lower tooling costs makes it an attractive option for many applications, including the following: Aerospace components: interior and exterior parts for aircraft, including cockpit panels, cabin components, and outer covers Automotive parts: door panels, dashboards, exterior body panels, and interior trims Consumer products: electronics covers, appliances, toys, and recreational equipment Industrial equipment: enclosures and covers for industrial equipment such as air compressors, generators, and machinery Medical devices: protective covers, enclosures, and housings for medical devices like MRI machines, surgical equipment, and X-ray machines Light Gauge Thermoforming Light gauge thermoforming produces parts using thin plastic sheets typically ranging from 0.005” to 0.050” in thickness. Like heavy gauge thermoforming, it involves heating the plastic sheet until it is pliable enough to be shaped by the vacuum over or into a forming tool. The desired shape is formed and, once the part has cooled, excess plastic is trimmed away. It is a highly efficient and cost-effective process for producing large volumes of small to medium-sized parts with short lead times and lower tooling costs. In addition, the thin-gauge plastic used in the process is typically made from materials like polyethylene terephthalate (PET), polystyrene (PS), and polyvinyl chloride (PVC). Advantages The following are the advantages of light gauge thermoforming: High efficiency and cost-effectiveness for producing large volumes Wide range of customization options of parts for unique product dimensions and branding requirements Lightweight parts and products Short lead times and quick turnaround times Minimal material waste Applications The versatility of light gauge thermoforming allows it to produce plastic parts and products, such as trays, clamshells, lids, and blister packs. Here are other common applications of the process in various industries: Automotive parts: interior trim, door panels, and exterior appliques Consumer goods: packaging, toys / games, and household items such as storage containers and organizers Electronics: cases, covers, and enclosures for electronic devices such as smartphones, tablets, and laptops Food packaging: trays, cups, and containers Medical packaging: trays and containers for medical devices and supplies Choose Jamestown Plastics for Premium Custom Plastic Products At Jamestown Plastics, we take pride in consistently delivering superior plastic solutions that meet and exceed our customers’ expectations! Our commitment to quality, advanced equipment, and skilled team enables us to handle custom plastic projects with precision and efficiency. We have implemented an ISO 9001:2015 certified Quality Management System to ensure top-notch quality control from design to production. In addition, our in-house design and tooling capabilities allow us to maintain tight control over all projects, while reducing lead times. Whether you need heavy gauge or light gauge thermoforming, we can do it all! Contact us today to learn more about our services and solutions.
Electronics Thermoforming Applications While the origin of thermoforming can be traced back to the 19th Century, it was the mid-20th century when it was first introduced to the electronics sector. The process entails heating plastic sheet and shaping it into a specific form to manufacture various electronic products or packaging for those products. This approach has revolutionized the [...]
Industries Leveraging Custom Plastic Thermoforming Plastic thermoforming has become increasingly popular as a top manufacturing process in various industries. Using heat and pressure to shape plastic sheet into proper forms provides an efficient and cost-effective solution for product manufacturing. Moreover, it presents numerous benefits over alternative manufacturing methods, including decreased tooling costs and improved material efficiency. Here are some of the [...]
Buffalo Business First: Clamtainer® revolutionizes packaging industry Buffalo Business First: It’s an exciting time at Jamestown Plastics, thanks to a brand-new product line with a catchy name and an innovative design that continues this company’s reputation for excellence. Clamtainer is a game changer in the field of transparent “clamshell” packaging and a vast improvement over flimsy traditional methodologies. Retailers and consumers alike are [...]
Why Thermoforming Could Be The Best Choice For Manufacturing Your Product Click to ExpandThis blog will cover the basics of thermoforming and how it helps different industries stay on top of the market with its practical and financial benefits. What Is Thermoforming? Thermoforming transforms plastic sheet into a 3-dimensional shape using heat, vacuum, and pressure. In this process, plastic is heated to its softening point and then [...]
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Unlocking the Future of Design With Plastic Thermoforming Techniques Thermoforming is a manufacturing process employed to shape thermoplastic sheet into specific designs. This method involves heating plastic sheet until it becomes pliable, then forming it over or into a mold to achieve the desired shape. Its versatility and efficiency make it a preferred choice for creating products ranging from disposable containers to intricate parts [...]
Medical Thermoforming Applications Thermoforming is a versatile manufacturing process that entails heating plastic sheets to a malleable state and then forming it with molds. Its significance in the medical field stems from its ability to produce cost-effective, lightweight, and disposable products that meet stringent quality requirements. Moreover, its accessibility, dependability, and efficacy make it indispensable for delivering safe [...]
Automotive Thermoforming Applications As the automotive industry continues to evolve, the need for fuel-efficient and lightweight vehicles has grown exponentially. This has led to a renewed interest in thermoforming, a technique that has existed since the 1940s. It is the process of producing parts by heating thermoplastic sheet material until it becomes pliable, then forming it into a [...]
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What Is Thermoforming? Thermoforming transforms thermoplastics through a series of processes, including heat, vacuum, and pressure, applied to a plastic sheet material. It utilizes a variety of machines to produce plastic products, including high-speed in-line thermoforming lines with robotic automation, light-gauge roll-fed machines, and larger sheet-fed machines for heavy-gauge products. This process allows parts to be produced with lower [...]
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Clamshells vs. Blisters Packaging is often the first point of contact between a customer and a product. As such, it can impact consumer perceptions. Therefore, choosing the most suitable type of packaging that protects the product and conveys the brand’s message effectively is essential. Clamshells and blisters are two popular packaging types that can provide various benefits, from [...]
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