Thermoforming

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Thermoforming is where a plastic or glass sheet is heated, formed to a specific shape in a mould and trimmed to create a usable product.

What is Thermoforming?

Thermoforming is a manufacturing process in which a thermoplastic or glass sheet is heated to a temperature where it becomes soft and flexible. Then the sheet is pressed into and stretched over the mould using air (both vacuum and compressed) pressure or pressed between moulds using mechanical force to form the desired shape.

Thermoformed glass for samsung galaxy
Thermoformed glass for Samsung galaxy

It’s very similar to vacuum forming but faster and used extensively for higher volume manufacturing of thermoplastics. Depending on the material, mould type, sheet thickness, and quantity, it might need trimming to create the final part.

Plastic thermoforming can be divided into the following two categories according to the material thickness.

  1. Thin gauge thermoforming (< 5 mm)
  2. Thick gauge thermoforming (> 3 mm)

As the name implies, the thin gauge process uses thin plastics to manufacture rigid or disposable packaging items such as plastic cups, food containers, lids, and blisters. In contrast, the thick-gauge process typically forms more durable cosmetic permanent parts such as vehicle door inside panels and electronics packaging.

The most common thermoplastics used in manufacturing process are;

What is Vacuum forming?

Vacuum forming is a type of thermoforming manufacturing process. The plastic is placed over a mould after being heated until it is soft and malleable. The plastic is then drawn onto the mould by a vacuum. The new shape is then formed by cooling the plastic until it becomes solid. The plastic can then be released from its mould by blowing the air back.

Vacuum forming is one of the earliest and most popular ways to handle plastic materials. Vacuum-forming products are ubiquitous and play a significant role in our daily lives. Plastic is frequently moulded into durable objects.

What is Glass thermoforming?

Thermoforming glass is a fairly new manufacturing process and came into prominence when Samsung introduced it through its flagship handset, Galaxy S6 edge. Using Glass is very similar to thermoforming plastics but differs because the glass is already cut to the right size, including the allowance needed for formed edges. It differs from glass blowing and is better suited for making flatter glass parts such as phone screens, glass tables and countertops.

Thermoforming Samsung Galaxy curved glass