【Pressure Forming】Exploring Diverse Thermoforming Applications: Product Development and Industry Trends at a Glance
📚 Table of Contents
Thermoforming during Product Development
Automotive and Transportation
Medical Devices and Equipment
Packaging and Displays
Appliances and Electronics
Consumer Products
Industrial Equipment
Product Prototyping Case Study - Beta design office
Thermoforming is a widely used manufacturing process for creating a variety of products. It involves heating a thermoplastic material until it is pliable and then shaping it into the desired form. Common applications include packaging, prototyping, food and beverage containers, and small-batch production.
In this guide, we will explore some thermoforming applications under current trends, categorized into three sections:
As consumers, we typically only see thermoforming in the final parts we use daily. However, thermoforming is often used throughout the product development process.
There are three main stages where thermoforming can be utilized:
1. Rapid Prototyping
This process is used to evaluate the functionality and design of an idea before investing in expensive production methods. Multiple iterations can be created quickly to test assembly paths, coatings, or post-processing options.
2. Tools and Fixtures
Thermoforming can be used to create tools for producing other products. For example, clear fixtures made with thermoforming can ensure consistent and precise production of parts.
3. End-Use Parts
Thermoformed parts are common in many industries, including automotive, medical, packaging, electronics, and more.
Which industries are applying thermoforming?
Automotive and Transportation
Thermoforming is widely used in the automotive and transportation industries to produce interior and exterior parts. These parts are made from materials like ABS, which can withstand high temperatures and pressures.
• Automotive Interior Components
Dashboards, door panels, and armrests
• Automotive Exterior Components
Bumpers, spoilers, and fenders
• Recreational Vehicle Components
RVs, motorhomes, and trailers
• Aircraft Components and Interiors
Windows, seats, armrests, and control panels
• Marine Components
Hulls, decks, canoes, kayaks, and interior components
• Transportation
Seats, interior panels, light covers, and gap covers
ABS car part made with a Mayku Multiplier pressure former
Medical Devices and Equipment
Thermoforming is an ideal process for manufacturing medical devices and equipment. It can provide parts that are sterilizable, durable, lightweight, and precise.
• Medical Device Housings
Hearing aids, ventilators, and defibrillators
• Medical Equipment
Hospital bed components, waste bins, containers, and sterile packaging
• Orthotics and Prosthetics
Custom braces, splints, and orthoses
Medical packaging prototype made with a Mayku Multiplier pressure former (Source: Oertli)
Packaging and Displays
Thermoforming is widely used in the packaging and display industries. These parts are typically made from materials like PETG, HIPS, and PVC, which offer transparency and excellent impact resistance.
• Food and Beverage Packaging
Clamshells and blister packaging, plastic trays
• Point-of-Sale Displays
Product stands
• Signage
Signs for indoor and outdoor use
PETG packaging made with a Mayku Multiplier
Appliances and Electronics
Thermoforming is an ideal solution for producing electrical and electronic components. It provides lightweight, strong, and heat-resistant parts with precision and consistency.
• Computer Housings
Desktop and laptop computers, switch boxes, control panels, and junction boxes
• Protective Casings
Laptops, measuring devices, and cameras
• Cooling Components
Door panels and liners
Computer mouse prototype made with HIPS using a Mayku Multiplier
Consumer Products
Thermoforming is a cost-effective way to produce consumer goods with intricate details and tight tolerances. It is an ideal solution for manufacturers who need to meet high standards.
• Toys
Remote-control cars, building blocks, puzzles, and action figures
• Sporting Goods
Helmets, protective gear, and fitness equipment
• Furniture Components
Armrests, backrests, and base components
Image from VASEAT
Industrial Equipment
Thermoforming is widely used in many industries and is a key method for prototyping and manufacturing specific applications.
• Agricultural Equipment
Panels, internal machine parts, sprayer housings, and feed containers
• Acoustic Components
Soundproofing and insulation
• Lighting
Light covers
Thermoformed lampshade prototype
Beta collaborated with Mayku to design a series of consumer accessories, prototyped using the Multiplier, showcasing various possibilities to designers and manufacturers.
Beta chose to design three consumer electronic products – mechanical keyboard housings, mice, and webcams – to demonstrate the precision and detail achievable with Multiplier-made parts. These products were designed for "users," featuring customizable housings that can be quickly swapped and replicated to test different textures and finishes.
Free Prototyping
Beta used a combination of 3D printing and pressure forming molds for product prototyping. Each mold took less than five minutes to make and was ready for immediate use. The Multiplier can capture intricate surface details, making it an excellent tool for experimenting with textures in molds.
Color, Material, Finish (CMF)
Beta used different CMF effects to highlight the Multiplier's functionality for makers and designers.
The Multiplier allows creators to quickly test ideas without outsourcing; keeping costs low and creativity flowing using various sheets.
Rapid, affordable 2mm molds can be tested immediately on the same machine, before moving on to flexible molds or choosing sheets thicker than 5mm to create injection mold quality housings.
Rapid, affordable 2mm molds can be tested immediately on the same machine, before moving on to flexible molds or choosing sheets thicker than 5mm to create injection mold quality housings.
Reduced Lead Times
Outsourcing custom mold designs or prototype components can be a lengthy process. Going back and forth on design drafts and then waiting up to 12 weeks for molds or components to be ready.
But with high-speed desktop thermoforming, you can go from idea to finished mold or part in 48 hours. Shorter lead times increase a company's sales potential and higher productivity.
►Learn more about thermoforming technology? Please refer to our Mayku guide:
【Thermoforming Applications】Vacuum Forming vs. Pressure Forming: What's the Difference? Find out here
【3D Printing Knowledge】 Application Guide for Creating Thermoforming Templates with FDM 3D Printing
【3D Printing Knowledge】 Application Guide for Creating Thermoforming Templates with SLA 3D Printing
【3D Printing Knowledge】 Application Guide for Creating Thermoforming Templates with SLS 3D Printing
►Learn more about Mayku desktop thermoforming equipment
• Mayku Multiplier Pressure Former
• FormBox Desktop Vacuum Forming Machine
References
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