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 materials, which are then heated and shaped into the final product. Understanding plastic manufacturing is crucial for producing high-quality, cost-effective products that meet the requirements of consumers and industries. This article provides an overview of the plastic manufacturing process and guidelines for selecting the optimal material for your application. Types of Plastics Before beginning the manufacturing process, knowing the type of plastic is essential because each material has different properties and are suited for various applications. Also, the type of plastic used in a product can affect its durability, resistance to heat and chemicals, tensile strength, and flexibility. Here are the two main types of plastics: Thermoplastics Thermoplastics can be repeatedly melted and reshaped without losing their properties. The materials are heated to their melting point, formed, and then cooled to solidify. They are also known for their flexibility, ease of processing, and low cost. The following are examples of thermoplastics: • Acrylic (PMMA) • Acrylonitrile butadiene styrene (ABS) • Amorphous Polyethylene Terephthalate (APET) • Polycarbonate (PC) • High-, Medium-, and Low Density Polyethylene (PE) • Polypropylene (PP) • Polyvinyl chloride (PVC) • Recycled Polyethylene Terephthalate (RPET) Thermosetting Plastics Also known as thermosets, thermosetting plastics solidify or set irreversibly when heated. They are formed by the reaction of a liquid resin with a curing agent. Once cooled, they cannot be remelted or reshaped. They are also known for their high strength and resistance to heat and chemicals. Examples of thermosets are as follows: • Cyanate ester • Epoxy • Polyurethane • Silicone • Vulcanized rubber The Plastic Manufacturing Process The plastic manufacturing process involves selecting raw materials, heating and shaping the materials, and cooling and solidifying the product. There are several types of techniques, each with its advantages and applications. The following are some of the most common methods: Thermoforming Thermoforming involves heating plastic sheet to a pliable forming temperature. Then, it is shaped by applying heat, vacuum, and pressure to create the product. In some cases additional trimming or finishing work is performed after thermoforming. Its high production rate and low cost make it a popular option for mass-producing simple to complex components. It also provides design flexibility for products with intricate details. The thermoforming process uses thermoplastics to manufacture clamshells, blisters, containers, trays, automotive and medical parts, and more. Compression Molding Compression molding involves heating a plastic material and compressing it under high pressure until it solidifies. Although it is more expensive than other methods, it offers high strength, a good surface finish, and excellent dimensional stability. Furthermore, it is used to produce industrial parts, automotive components, and consumer goods. Injection Molding Injection molding involves heating, mixing, and injecting the material into a mold, which cools and solidifies it into the required shape. It uses thermoplastic pellets to manufacture components for multiple industries. The investment for this process is high, but the cost per part is low once the tooling is complete. Extrusion Plastic extrusion is a manufacturing process in which thermoplastic material is melted and shaped into a continuous profile or shape. However, it typically creates parts with lower tolerances and inferior surface finishes compared to other techniques. Other plastic manufacturing processes include the following: • Blow molding • Polymer casting • Rotational molding • Vacuum casting Jamestown Plastics for High-Quality Manufacturing Services Jamestown Plastics is your best option for high-quality plastic manufacturing services! We specialize in both heavy-gauge and light-gauge plastic thermoforming with high-speed CNC machining capabilities for precise and efficient parts. We also have advanced in-line thermoforming lines with robotic automation and multiple component assembly technologies. We have the expertise and resources to help you improve product performance, reduce product cost, save manufacturing time, and reduce shipping damage. Contact us now to learn how we can help you achieve your manufacturing goals.
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 [...]
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 [...]
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 [...]
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 [...]
The Ultimate Guide to Plastic ManufacturingIn 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 […]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
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 [...]
