Thermoformed Plastic Manufacturing Process
At Arrowhead, we specialize in the thermoformed plastic manufacturing process, offering a wide range of forming techniques to produce reliable, high-performance plastic components. Thermoforming—commonly referred to as vacuum forming—involves heating a flat sheet of thermoplastic material until it becomes pliable. The softened sheet is then shaped over a mold using vacuum, pressure, or gravity, depending on the method used. After forming, the sheet is cooled, hardened, and trimmed to produce the final part.
This process is ideal for creating durable, lightweight plastic parts across industries, including transportation, medical, industrial equipment, and consumer goods. From dunnage trays and dashboard panels to protective covers and retail displays, the thermoformed plastic manufacturing process offers both design flexibility and cost efficiency.
Thermoforming (Vacuum Forming)
Vacuum forming is the most widely used method within the thermoformed plastic manufacturing process, valued for its simplicity and scalability. In this process, a thermoplastic sheet is clamped in a frame and heated until it reaches a malleable state. Once the sheet sags under its own weight, it is positioned over a mold, and vacuum pressure is applied to remove the air between the sheet and the mold. The vacuum pulls the sheet tightly over the mold’s surface, creating an exact impression.
Once cooled, the formed plastic is removed and trimmed to its final shape. This method is ideal for both prototyping and production, accommodating various part sizes and geometries. Vacuum forming is especially well suited for applications like display panels, trays, guards, and structural housings that require moderate complexity and quick turnaround.
Plug Assist Thermoforming
Plug assist thermoforming is an enhanced version of vacuum forming that improves material distribution during the forming phase. In this variation of the thermoformed plastic manufacturing process, a plug is introduced to mechanically push the heated plastic into the mold before vacuum is applied. This helps guide the material into corners and deep cavities, ensuring more even wall thickness throughout the part.
Plug assist is essential when forming deep-draw or detailed components where straight vacuum forming could lead to excessive thinning. By pre-shaping the material, this method improves part strength, aesthetic consistency, and material utilization, especially in applications requiring tight tolerances and structural durability.
Pre-Draw Box Thermoforming
For complex molds or applications requiring exceptionally consistent wall thickness, the use of a pre-draw box is a valuable enhancement to the thermoformed plastic manufacturing process. This method involves pre-stretching the heated thermoplastic sheet before it comes into contact with the mold. The result is better material distribution, reduced stress in the final part, and fewer cosmetic flaws.
The pre-draw box technique is especially useful for parts with symmetrical shapes or those exposed to varying stresses in use. It also helps prevent material thinning in high-draw areas and enhances the overall appearance of the formed part by minimizing surface irregularities caused by challenging mold geometries.
Drape Forming
Drape forming is a low-pressure variant of the thermoformed plastic manufacturing process, where gravity—rather than vacuum—is used to form the heated plastic sheet over a mold. Once softened, the plastic drapes naturally over the mold and takes on its shape. This method is particularly effective for parts that require exceptional clarity or extremely uniform wall thickness with minimal stretching.
While limited to simpler geometries without tight curves or sharp corners, drape forming is advantageous in applications like lighting panels, see-through guards, and display covers. It can also be combined with double-sided tooling or mechanical assists to form more nuanced shapes, expanding its usefulness in certain niche applications.
Strip Heating and Bending
Strip heating and bending is a straightforward and cost-efficient thermoformed plastic manufacturing process used when only a linear bend is required instead of full 3D forming. This method uses a heated rod (usually a calrod) to soften a narrow band of plastic sheet along a specific line. The heated section is then bent over a form to the required angle and allowed to cool.
This process is perfect for producing plastic components with clean, uniform bends and minimal waste. It’s commonly used for items like signage, enclosures, and point-of-purchase fixtures. While limited in complexity, strip heating and bending is a valuable forming method for low-volume production or simple geometries.
Vinyl Wrapping
Vinyl wrapping is a multi-step finishing technique commonly used in conjunction with the thermoformed plastic manufacturing process to enhance a part’s tactile feel and appearance. A rigid part—often thermoformed from ABS, polycarbonate, or fiberglass—is first trimmed and coated with adhesive. Then, a vinyl sheet is heated and vacuum-formed over the part, creating a seamless, soft-touch surface.
This process is popular in automotive and consumer applications such as dashboards, instrument panels, and control enclosures. Vinyl wrapping enables a hard structural core to have a premium outer finish without the need for expensive multi-material molding. Innovations in multi-layer thermoformable sheets with TPE cap layers are also emerging, allowing some vinyl wrapping steps to be integrated into a single forming cycle.
Though material choices are still somewhat limited, vinyl wrapping offers an effective way to blend form, function, and aesthetics in thermoformed plastic parts.
Your Partner in the Thermoformed Plastic Manufacturing Process
At Arrowhead, we’ve built decades of experience perfecting the thermoformed plastic manufacturing process, offering a full range of forming methods to meet your part performance, design, and budget requirements. Whether you’re developing a one-off prototype or scaling to full production, our expert team is here to help you choose the right materials and processes for your application.
From vacuum forming and plug assist to vinyl wrapping and drape forming, we have the tools and know-how to bring your plastic components to life—efficiently, affordably, and with attention to detail.
Have a project in mind? Contact us today to speak with our team and request a quote. Let’s build something great together.