What Is Plastic Manufacturing? Benefits of Using Plastics in the Manufacturing Industry Thermoforming Other Plastic Fabrication Processes In the plastics industry, each polymer option presents unique mechanical characteristics. As a result, it is possible to fabricate almost anything with every material, and most plastic manufacturing processes cover a vast array of product development requirements. In addition, these processes have been an integral part of the industry. They involve designing, producing, and assembling products using various techniques. Jamestown Plastics is recognized as one of the world’s most diversified custom plastics manufacturers. We are committed to providing a superior service level to our customers, which is best attained through experience and technical professionalism. We are also equipped with state-of-the-art equipment and highly experienced staff, enabling us to ensure consistency from the design phase through production. What Is Plastic Manufacturing? Plastic manufacturing is the method of designing, fabricating, and assembling a product composed of plastic materials or composites. Due to the variety of product or material options, numerous plastic part manufacturing techniques have been developed. Each method has pros and cons that make it suitable for fabricating specific designs and components. There are two major categories of plastic: thermosetting and thermoplastic. They are classified based on their ability to be molded into desired shapes under pressure and temperature conditions. Thermosetting Thermosetting plastics are polymers that become irreversibly tight and rigid upon heating. The polymer begins as a liquid or soft solid but quickly hardens due to heat-driven chemical reactions that increase polymer chain cross-linking. Some examples of thermosetting plastics are fiberglass, vulcanized rubber, epoxy resin, polyurethane, and polyester resin. Thermoplastic Thermoplastics can be softened by heating and processed via injection molding, thermoforming, and blow molding. This material hardens once cooled and retains its chemical properties despite repeated heating and cooling. Examples of thermoplastics include polyethylene and polypropylene. Benefits of Using Plastics in the Manufacturing Industry Plastic is an extremely versatile and adaptable material, making it applicable to virtually every industry. In addition, it offers the following advantages that make it superior to other materials in the manufacturing sector: Durability Plastic is more flexible and durable than most metals. Its high structural strength allows it to withstand extreme pressures and hostile environments. Cost-Effectiveness One of the main benefits of using plastic in manufacturing is the cost of producing and using the finished parts. It is generally less expensive than other materials and can easily be made in larger quantities. Productivity Manufacturing a plastic part takes a shorter time than metals such as steel, copper, and aluminum. Moreover, most metals require finishing processes in the final phase of manufacturing, whereas plastic parts may not. Energy Efficiency Plastic is a lightweight material that enables manufacturers to create lighter products and packaging. It also requires less energy to manufacture and transform into final components than metals, glass, and other materials. Moreover, plastic products, including sealants, insulations, and building materials, contribute to the energy efficiency of infrastructures. Thermoforming: An Efficient Plastic Fabrication Process Thermoforming is a cost-effective technique for producing intricate shapes from plastic. It transforms thermoplastics by applying heat, vacuum, and pressure to 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 plastic manufacturing process enables the production of parts with lesser production costs and may not require additional machining or tooling. As a result, it is a preferred technique for manufacturing components, including clamshells, blisters, automotive appliques, reusable totes / trays, covers, and bumpers. Advantages of Thermoforming Thermoforming provides various advantages that make it a suitable plastic part manufacturing method. Among the benefits of thermoforming plastic are the following: Allows for adding details and creating custom designs Economical Excellent for manufacturing both small and large parts Has a short prototyping and development cycle Requires lower tooling investment compared to other processes Because of the mentioned advantages, thermoforming is frequently used across multiple industries, including electronics, agriculture, automotive, consumer products, packaging, medical, and marine. The Thermoforming Process The thermoforming process begins with heated plastic sheet, typically from 0.005” to 0.75” thick, formed into the required shape. This is accomplished using a vacuum, air pressure, or mechanical force. After the plastic has cooled, it is trimmed and any extra features are added with specialized equipment such as high-speed CNC machining, high-precision robotic trimming, and routers. For heavy-gauge applications, the part can typically be used for its intended application after all requested adjustments have been made. In most cases with light-gauge in-line thermoforming, the parts are finished and ready to use when they come off the machine. Thermoforming plastic sheet necessitates specialized equipment to heat and shape. This consists of an oven, a vacuum source, and a tool for forming. The oven is utilized to heat the thermoplastic until it is moldable enough to be formed by the vacuum over or into the forming tool. Thermoforming Techniques There are three distinct thermoforming techniques: vacuum forming, pressure forming, and twin sheet forming. Vacuum Forming: This technique involves heating plastic sheet across an open mold while using a vacuum to form a part. It uses a maximum pressure of 15 psi to help shape the plastic sheet. Pressure Forming: This method utilizes a vacuum and positive air pressure but creates three to four times greater force than vacuum forming. Additionally, it achieves intricate details and textures on the mold without incurring additional costs. Twin Sheet Forming: This process requires simultaneously heating and forming two plastic sheets with two molds, one at the top and one at the bottom. In addition, a fused joint is needed around the perimeter of the mold, and air pressure is injected between the plastic sheets. Considerations When Selecting a Plastic Thermoforming Manufacturer Each plastic thermoforming manufacturer provides a distinct set of capabilities; therefore, it is necessary to find one specializing in a specific project’s essential aspects. Consider the following factors when selecting a thermoforming partner: Material availability and expertise Equipment and manufacturing capabilities Design and engineering team competence Production capacity and additional services Standards and certifications Pricing Other Plastic Fabrication Processes Aside from thermoforming, several other processes are frequently used in manufacturing plastic products. Here are some examples: Injection Molding: This method is one of the most common plastic processing techniques and is considered a standard method in all plastic fabrication companies. It involves melting plastic pellets — thermosetting or thermoplastic — before injecting them into a mold cavity at pressure. Vacuum Casting: This is a cost-effective technique for custom plastic manufacturing. It involves producing small, functional plastic components or prototypes using a master model with a high-quality surface finish. Blow Molding: This popular plastic fabrication technique involves inflating heated plastic tubes to create hollow plastic components. It utilizes thermoplastic pellets that are melted into a hollow tube before the forming step, which may include extruding, injecting, or stretching. Why Choose Jamestown Plastics Jamestown Plastics is committed to customer satisfaction by adhering to ISO 9001-certified quality standards for testing, inspection, traceability, process control, and documentation. Our customers also value this dedication, as we consistently perform well on key success metrics, such as on-time delivery, product acceptance, and overall client satisfaction. We offer plastic thermoforming services to numerous industries, including the automotive, consumer goods, electronics, medical, and general industrial sectors! Further, our team also provides value-added services to expedite the market delivery of the products. Partner With Jamestown Plastics for High-Quality Plastic Manufacturing Services At Jamestown Plastics, we guarantee that the methods and expertise we provide to customers are of the highest quality and standard. We perform our design and tooling work in-house, giving us complete control over every aspect of a project and allowing us to reduce lead times as needed. Our experts can help you in producing plastic products of the highest quality! Contact us for more information about our products and services.
Thermoforming 101: The Process That’s Revolutionizing Product DesignThermoforming is a manufacturing process that shapes plastic sheet into specific forms using heat and pressure. It is commonly employed to produce various products, such as packaging, trays, containers, and automotive components. This method offers cost-effectiveness, rapid production cycles, and the ability to easily create complex shapes. What is thermoforming? In this article, we will answer [...]
Dunnage Trays: Protecting Products Every Step of the Way Click to Expand Dunnage or packaging trays are specialized containers used in the manufacturing and logistics industries to securely hold and transport products or components. They are made from materials like plastic or metal and are designed to protect items from damage during storage or transit. Moreover, their configuration often matches the form of the things [...]
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 [...]
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 [...]
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 Plastic Medical Trays Are Essential for Safe and Sterile Procedures Click to Expand Plastic medical trays are often used in healthcare settings to assist in keeping those areas contamination-free. These trays can also be used for organizing and sterilizing healthcare instruments and equipment, transporting medications and supplies, for specimen collection (providing a clean and secure environment for handling biological samples), or found within labs. Plastic medical [...]
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 [...]
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 [...]
Material Matters: Choosing the Right Medical Tray Plastic for Safety and Durability Click to Expand A medical tray serves a variety of purposes in healthcare settings, primarily in holding sterilized parts and equipment. It is also used for organizing and transporting medical instruments or facilitating efficient workflows during medical procedures. A medical tray plastic is a specialized material used to manufacture these trays. This blog discusses the types of [...]
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 [...]
Understanding the Plastic Manufacturing Process Click to Expand Plastic is a versatile material that can be molded into a wide range of shapes and sizes, making it ideal for various applications. From food packaging and containers to medical equipment and car parts, plastic manufacturing plays a crucial role in the production of items. The process begins with the selection of raw [...]
Reshoring and Nearshoring In recent years, global supply chains have encountered challenges such as trade conflicts, political volatility, natural calamities, and the COVID-19 pandemic. Consequently, numerous companies in the United States have had to reconsider their supply chain approaches. For instance, some are halting decades of outsourcing and offshoring by bringing their production back home or closer to [...]
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 [...]
Reduce, Reuse, and Recycle: How to Incorporate the 3R’s Into Any Business That Deals With Plastics There is a lot of plastic in the world, with 31.9 million metric tons of plastic waste being improperly disposed of globally. Luckily, green packaging is making an indent in our society, but until it’s fully implemented, it is important to do the most we can, at both a manufacturer and consumer level, to reduce [...]
Heavy Gauge vs. Light Gauge Thermoforming 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 [...]
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 [...]
Choosing the Right Plastic Products Manufacturing Partner Click to ExpandPlastic is one of the most preferred manufacturing materials due to its durability and ductility, with different components used in the medical, automotive, electrical, aerospace, marine, and construction industries. In particular, the plastic thermoforming process has upsides over other plastic, metal, and FRP manufacturing techniques, including low tooling costs and faster product development. Establishing [...]
