PLASTIC THERMOFORMING

Custom Thermoforming solution, large parts thermoforming

Excelite Plastic Thermoforming Services

Plastic thermoforming is a manufacturing process that applies vacuum or pressure to shape plastic sheets, commonly used across various industries. At Excelite, we focus on thermoforming polycarbonate and acrylic sheets for applications such as polycarbonate domes, skylights, boat windows, helmet visors, and riot shields.

Thermoforming methods include drape forming, heat forming, and vacuum forming, vacuum and drape forming being the most efficient and flexible. Polycarbonate sheets, compared to acrylic sheet, require more precise control due to their higher water absorption rate (0.3%), which necessitates drying before thermoforming to avoid bubbling.

Additionally, the hard coating on polycarbonate sheets may crack during heating, as it’s less flexible. If your project involves thermoforming, consult Excelite for a specially designed hard coating that can withstand the process.

Our Production Capabilities

Rapid thermoforming prototyping
Rapid custom plastic moulding
In house printing and finishing
Large polycarbonate and acrylic parts thermoforming
Thermoform-able coatings
Multi-part Projects include edge scraping, silk-screening printing, assembly, bonding, polishing

Thermoforming Plastic vs Injection Molding

Choosing between thermoforming and injection molding affects tooling investment, lead time, and per-part cost. Excelite works with polycarbonate, ABS and acrylic sheets for formed plastic components. Compare the factors below to match the process to your part geometry, production volume, and delivery schedule.

Tooling cost

Thermoforming often uses simpler, single-sided tooling, which can cost less than injection-molding tooling. Actual cost depends on part size, design, tolerances, and production requirements.

Production volume

Thermoforming can be cost-effective for prototypes, lower-volume programs, and large parts. Injection molding may reduce per-part cost at higher volumes as tooling costs are spread across more parts.

Lead time

Simpler thermoforming tools can shorten tooling and first-article timelines. Injection-molding projects may require more time for mold design, machining, sampling, and validation.

Design freedom and part size

Thermoforming suits large panels, windows, domes, housings, and formed covers. Injection molding is well suited to parts with integrated ribs, bosses, clips, and detailed features.

Materials

Thermoforming uses formable plastic sheets, including polycarbonate, acrylic, and ABS grades. Injection molding uses compatible plastic resins in pellet form. Select material according to impact, clarity, weather exposure, and part requirements.

Tolerances and surface detail

Thermoforming can produce consistent large parts, though forming depth may affect wall thickness. Injection molding can produce repeatable fine details on both sides of the part. Confirm required tolerances against the design and intended use.

When to choose thermoforming

Choose thermoforming for large formed parts, sheet-based materials, or projects where lower upfront tooling investment and design flexibility matter. Polycarbonate and acrylic sheets can suit applications such as panels, shields, windows, and equipment covers.

When to choose injection molding

Choose injection molding for higher-volume programs or parts that need detailed, repeatable features. The tooling investment may be justified when production volume, part design, and expected mold life support the total cost.

Need help choosing the right one? Contact Excelite to discuss your part requirements and request a quote for custom thermoformed parts.

Types of Plastic Thermoforming Processes

Vacuum thermoforming

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Pressure Forming

Use air pressure to force the heated plastic sheet into the mold. It's an affordable manufacturing process and can make large sizes.

Drape Forming

Use gravity to drape the heated perspex sheet over the mold. Very affordable, quick manufacturing process

Advantages of Plastic Thermoforming

Versatility: Custom thermoforming can be used to create a wide range of shapes and designs, making it suitable for a variety of applications.
Much lower tooling costs when compared to injection molding
Quick process: Thermoforming is a quick process compare to injection moulding.
Capability to do very large custom thermoformed plastic parts
High-quality finishes: Thermoforming can produce parts with high-quality finishes, reducing the need for additional finishing processes

Disadvantages of Plastic Thermoforming

Limited to certain shapes: While thermoforming is versatile, it can’t be used to create complex or intricate shapes.
Temperature Sensitivity: Polycarbonate has a higher thermal sensitivity compare to Acrylic sheets, which means that proper heating and cooling parameters must be carefully controlled during thermoforming to achieve consistent results and prevent material degradation.
Warping and Distortion: Polycarbonate has a relatively high coefficient of thermal expansion, which can result in warping or distortion of the formed parts, especially if not properly controlled during heating, forming, and cooling stages of thermoforming.
Brittleness: Polycarbonate is easy to scratch and crack under certain conditions. During the thermoforming process, the material may become stressed, leading to potential brittleness in the formed parts. Acrylic sheet is more scratch resistant compare to polycarbonate sheet.

Plastic Thermoforming Process

Excelite’s plastic thermoforming process turns flat thermoplastic sheet into finished panels, windows, visors, and housings. The sequence below is how we move from sheet stock to trimmed, finished parts in a fabricator-controlled workflow.

1. Sheet selection and preparation

Select gauge, grade, and coating for the end use. Polycarbonate often needs drying before heat to reduce moisture-related bubbles. Masking, nesting, and clamp frames are set so the sheet forms cleanly.

2. Heating

The sheet is heated evenly, typically with radiant heaters, until it reaches forming temperature and softens without scorching coatings or overheating edges.

3. Forming (vacuum, pressure, or drape)

Vacuum forming pulls the hot sheet onto the mold. Pressure forming adds positive air pressure for sharper detail. Drape forming uses gravity and light assist for gentle curves and large optical parts.

4. Cooling

The part is held on the mold while it cools and sets. Controlled cooling limits warpage, especially on polycarbonate with higher thermal expansion.

5. Trim

After demold, excess sheet is trimmed by CNC routing, saws, or fixtures so edges match the drawing. Scrap can often be recycled depending on grade and coating.

6. Finishing

Post-forming may include CNC machining, polishing, drilling, bonding, printing, and assembly so optical and structural parts meet the print under one fabricator workflow.

From prototype to production, Excelite aligns heat profiles, mold design, and finishing. Multi-step programs can combine forming with CNC machining and custom plastic fabrication under one roof.

Why Choose EXCELITE For Custom Plastic Thermoforming

With over 15 years of polycarbonate fabrication and machining experience, Excelite specializes in the fabrication of polycarbonate and acrylic sheet products, ensuring top-notch quality and precision. We are committed to providing the best manufacturing solutions tailored to your unique requirements.

Whether you have a detailed drawing or just an idea, our team of professionals is ready to turn your vision into reality. Enjoy the benefits of our services, including:

In-house Design & Tooling
Exceptional Accuracy (+/- 0.005″ Tolerances)
Comprehensive OEM & ODM Services
ISO 9001:2008 Certification
Direct Manufacturer Advantage

We invite you to partner with us and experience a seamless, efficient, and quality-driven production process.

EXCELITE Plastic Thermoforming Case Study

Large size thermoforming

Super large size Plastic thermoforming for boat window. 2000*3000mm

Pressure forming and CNC machining

Clear thermoformed kayak

Polycarbonate thermoformed Kayak,

Vacuum Thermoforming and pressure forming, CNC machining

Polycarbonate caravan window

Hard coated polycarbonate sheet, thermoforming, polycarbonate bonding, assembling

Polycarbonate Camera Shield

Security camera dome, replacement polycarbonate dome, acrylic dome with abrasion resistant coating

Helmet Visor

Motor helmet visor, Eye and face protection, PPE, face shields, with formable Antifog coating

Industrial equipment

Incorporated in machinery parts, fixtures, and toolings, such as jigs and custom components for manufacturing processes.

plastic Materials for thermoforming

Polycarbonate Sheet

As a clear plastic sheet, Polycarbonate sheet is one of the best plastic for thermoforming

Acrylic Sheet

Acrylic sheet can be formed into almost any shape, like Large Plastic Domes, Acrylic dome, Acrylic sphere, etc.

ABS

ABS is an opaque thermoplastic polymer that is commonly used in both thermoforming and injection molding manufacturing.

Thermoformed Plastic Part Finishing and Assembly

Frequent Asked Questions

1. Is thermoforming competitive with injection molding for plastics?

Thermoforming and injection molding are two key plastic manufacturing methods, each with unique benefits.

Thermoforming heats and shapes plastic sheets over a mold, making it more cost-effective for prototyping and low-volume production with cheaper, adjustable molds. It also allows for more material options and the production of larger parts with textured finishes.

Injection molding, while initially expensive due to complex molds, is highly efficient for large-scale production, quickly producing high volumes of precise parts.

The choice between them depends on project needs, with thermoforming being ideal for flexibility and size, and injection molding excelling in mass production. Both methods complement each other in offering versatile solutions.

2. What are the popular applications of thermoforming plastic?

Thermoforming is a versatile process used in many industries, from food packaging to aerospace and auto parts manufacturing. Since most industries work with thermoplastics at some point, understanding thermoforming is essential.

There are two main types of sheets: thin-gauge and thick-gauge. Thin-gauge sheets are commonly used for rigid, disposable packaging, while thick-gauge sheets have broader applications. These include durable surfaces for automobiles, window enclosures, building products, signs, and electronic equipment.

The possibilities for thermoformed plastic products are vast, but the process is not one-size-fits-all. The right material, techniques, and expertise are key to creating optimal results for each application.

Recent developments in thermoforming include advancements in non-composite sheets that add value to specific industries. Additionally, thick sheets are sometimes converted into composite sheets, resulting in thinner-walled parts that are ideal for weight-sensitive applications.

3. Where is Excelite located, and what areas do you serve?

Excelite’s plastic fabrication center is located in Suzhou, China, supplying a wide range of polycarbonate sheets and offering plastic fabrication services globally, including to the USA, Mexico, Chile, UAE, France, Germany, and Singapore. We also have an overseas branch in Victoria, Australia, and provide polycarbonate sheets with nationwide shipping across the country.

4. The Best Plastic for themo forming or Vacuum Forming

People often ask which plastic is best for vacuum forming. Typically, vacuum forming uses thermoplastics, which become flexible at certain temperatures and solidify once cooled. One commonly used material is high-impact polystyrene (HIPS), known for its flexibility and ability to be molded into almost any shape.

Polycarbonate (PC) is another popular choice for vacuum forming. It’s extremely tough and resistant to flames, chemicals, and water, making it ideal for medical equipment and food manufacturing machinery. It’s also easy to mold, trim, and fabricate.

Acrylic (PMMA) is another widely used plastic for vacuum forming and thermoforming due to its versatility and ease of use.

5. How quickly can I get my parts?

Lead times are 2 to 3 weeks for prototypes and 4 weeks for production runs.
Some special urgent orders can be discussed beforehand.

6. Is Vacuum Forming Expensive or Cheap?

One of the key advantages of vacuum forming is its cost-effectiveness. While the initial machinery investment may be significant, it is highly versatile and can produce a wide variety of products. Additionally, once molds are made, they can be reused repeatedly for mass production, making vacuum forming one of the most affordable methods of plastic fabrication.

7. What is the difference between pressure forming and vacuum forming?

Pressure forming provides a contrast to vacuum forming. The use of high pressure to push and pull the plastic tightly against the mold allows for greater precision, detail, and sharpness, while still being suitable for forming large plastic parts with ease.

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At Excelite Plastics, every project is unique.