All posts by : Emanda Gibson

This is actually a question we get quite a bit, so we thought we would address it in an post. Before we get into the process of thermoforming polycarbonate, though, let’s take a moment to discuss the characteristics of polycarbonate. To start, polycarbonate is a transparent plastic material. Its chemical conclusion is reached by combining bisphenol-A and phosgene. Polycarbonate is naturally a transparent plastic and, as a result, it is popular for vehicle head lamps and other lighting situations where transparency is critical. In addition to transparency, polycarbonate is a tough plastic that routinely scores well on impact strength tests. For that reason, it’s also frequently used in situations where a bullet-proof material is needed.

Okay, so on to the thermoforming part. We have covered this more extensively in another post. To sum up here, though, thermoforming is a process in which plastic sheets, of which polycarbonate is, are heated to a point that they form to shape by means of core and cavity. For polycarbonate, the temperature needs to be between about 300 and 500 degrees Fahrenheit. The final product should be extruded to sheets and thoroughly dried to prevent the formation of bubbles or haze.

To learn more about our thermoforming processes and how they can benefit your organization, give us a call at 1-800-467-4561 today!

One of the reasons that plastic thermoforming is such a popular choice is because of its ability to be used in a number of different industries with equal effectiveness. For instance, Acrylonitrile Butadiene Styrene (ABS) and High Impact Polystyrene (HIPS) are both thermoplastics, but they have different properties, including: Mechanical Properties like elasticity and impact strength; Thermal Properties like thermal expansion; Electrical Properties like dielectric strength; and other general properties like density.

So, depending upon the end-product needs, plastic thermoforming can use about 18 different common thermoplastics to build pieces and parts that have the best characteristics for any given application. This gives a thermoplastics company like Spencer Industries the ability to create thermoform plastics for a number of different applications, including medical carts, refrigeration units, golf carts, industrial equipment, tractors, and more.

In Conlusion

At Spencer Industries, we leverage the experience we have accrued since 1969 in formulating creative thermoforming solutions for industries as varied as refridgeration, transportation, UTVs, agriculture, and more.

If you have a thermoforming project at hand, call us at 1-800-467-4561 today. Let us put our expertise to work for you!

Before we get into the dynamic applications of thermoform packaging, we should quickly go over what thermoforming is in the first place, as it will bring clarity to its widespread use in packaging.

In short, thermoforming is a process wherein a plastic sheet is heated to a temperature that makes it pliable enough for forming into specific shapes in molds. After the molded shape is formed and cooled, it is trimmed as necessary to reach the final specs of the required design.

Popular Uses Of Thermoform Packaging Technology

There are a myriad of different ways in which thermoforming packaging can be put into practice. Three of the most common applications include: trays and lids, clamshells, and blisters.

• Trays and Lids. Trays are commonly used for items like sets of tools, boxes of chocolates, or even disposable deli platters. The lids, then, would be used to cover the trays.
• Clamshells. Clamshells are custom-fit packages that are usually made from rigid Polyvinyl Chloride (PVC). Each clamshell will often feature a hinge (like the back of a clam), that folds over to secure a product (or products) in place, via buttons or snaps that fit together to lock the product in place. Sometimes clamshells will also have a hole at the top for hanging on a peg at a retail outlet.
• Blisters. Blisters are custom-formed cavities, also referred to as “pockets” that are usually glued to a printed cardboard backing once the product is in place.

While there are certainly other applications for thermodynamic packaging, these are among the most popular in use today.

In Conclusion

At Spencer Industries, we leverage the experience we have accrued since 1969 in creating innovative thermoforming solutions for industries as diverse as refrigeration, transportation, UTVs, agriculture, and more.

If you have a thermoforming project in mind, give us a call at 1-800-467-4561 today. We’d be happy to put our expertise to work for you.

Thermoforming is a manufacturing process in which a plastic sheet is heated to its specific pliable forming temperature—this can vary from plastic to plastic—then formed to a precise shape in a mold. To finish, it is trimmed to make a usable plastic product. The plastic sheet—also known as a “film” when referring to thinner gauges and particular material types—is heated to a temperature hot enough to allow it to be stretched into or across a mold before being cooled to its final form. A basic form of thermoforming is known as vacuum forming.

In its most rudimentary form, a small machine heats small plastic sheets and uses a vacuum to stretch them over the product mold. You’ll find this themoforming process frequently used in prototyping. In more involved applications, large production machines employ an assembly-line like process to quickly heat plastic sheets and trim the final parts. Depending upon the part being produced, this process can turn out thousands of finished items each hour.

Thermoforming is distinct from other forms of plastic molding, such as blow molding, injection molding, and rotational molding. Thin-gauge thermoforming is primarily used in the manufacture of clamshells, disposable cups, lids, and the like. Thick-gauge thermoforming, like the kind we do at Spencer Industries, is used in a wide variety of industries in products as disparate as refrigerator door liners, vehicle interior panels and fender flares, medical carts.

At Spencer Industries, we also recycle. Scrap plastic from a product run is collected and turned back into extruded sheet and used in subsequent product runs when possible.

To learn more about our thermoforming processes and how they can benefit your organization, give us a call at 1-800-467-4561 today!

There are a variety of common thermoforming materials and each have their own strengths and drawbacks. Which plastic will be the best for your application really comes down to the application itself. Some of the common factors to take into consideration can include:

• Stiffness. How rigid does the final plastic product need to be in order to fulfill its intended use?
• Hardness. How hard does the final plastic product to be in order to withstand any chipping, cracking, or abrasions that may come along with its intended use?
• Impact Strength. How much impact will the final plastic product need to endure before it finally breaks?
• Heat Deflection. How much heat will the final plastic product need to withstand before it begins to distort?
• Tensile Strength. How much resistance will the final plastic product need to handle before it is pulled apart?
• Forming Range. How hot does the plastic sheet need to be before it can be thermoformed?

There are more, of course, but you get the idea. If you haven’t already done so, you’ll want to make note of these types of needs. Once those needs are established, they are compared to a variety of different plastics to find a fit that best matches your needs and budget. Below are some of the most common plastics used in thermoforming, as well as some basic characteristics of each.

• Acrylonitrile Butadiene Styrene (ABS). One of the most commonly used thermoplastics. It features a good impact resistance rating. It’s available in a host of different colors and flame-retardent grades (UL94-V0).
• High Density Polyethylene (HDPE). The advantages of HPDE are that is it resistant to cold temperatures, as well as being very resistant to impact and chemical interaction. The tradeoff is that it offers less dimensional stability than some other thermoplastics.
• High Impact Polystyrene (HIPS). Its low cost makes it a popular option. That it is easy to form and comes in quite a few colors doesn’t hurt anything either.
• PMMA/PVC blend (KYDEX). Another popular option, KYDEX is impact-resistant and chemical-resistant. It comes in a lot of colors and flame-retardant grades (UL94-V0). Combine all of this with a highly-cosmetic appearance and it makes for a great general-purpose thermoplastic.
• Polycarbonate (PC). Being a clear material limits its use in certain applications, but its resistance to high temperatures and good impact strength continues to make it a popular choice.
• Polyetherimide, Ultem (PEI). This autoclavable material has an amber-colored appearance and is quite resistant to high temperatures.
• Polyethylene Terephthalate Glycol (PETG). This clear material forms well and is impact resistant.
• Polymethyl Methacrylate, Plexiglass (Acrylic). It can come as a clear material or in a number of different colors. Acrylic is really resistant to abrasion and easy to fabricate. Impact-resistant grades are available, as well.
• Polypropylene (PP). Very similar to HDPE, PP is chemical-resistant, as well as being resistant to higher temperatures and impact. Like HDPE, the flipside is that it is not as dimensionally stable as some other materials.
• Polyvinyl Chloride (PVC). Valued because it is rigid and impact-resistant, PVC also comes on flame-retardant grades (UL94-V0). PVC, however, often has a limited availability.
• Thermoplastic Polyolefin (TPO). From a fabrication perspective, TPO can be somewhat difficult to form, particularly if we are talking about deep-draw shapes. That aside, its excellent impact resistance and available high-gloss finish makes it an ideal material for outdoor use.

In Conclusion

A host of different thermoplastics can be used for your next project. To find the right one, start by assessing the needs and environment of your final product and work backwards from there to find a plastic with the right qualities for you.

To learn more about the best plastic to suit your plastic thermoforming needs, give Spencer Industries a call at 1-800-467-4561 today!

Most of us encounter all kinds of plastic products in our daily lives, from plastic bags, to water bottles and food containers, to sports equipment, to PVC pipes, to insulative products, to adhesives and sealants, and so much more. Plastics are used in product packaging, building construction, electronics, transportation, and nearly every industry. Versatile, lightweight plastics are used for all kinds of applications, adding convenience and cost-effectiveness to many areas of modern existence.

What are plastics? Broadly speaking, plastics are substances made from polymers; there are two main categories: thermoplastics and thermosets. What, exactly, are thermoplastics? What separates them from thermosets? What are the different types of thermoplastics and how are they used? Here’s what you should know.

Characteristics Of Thermoplastics

To understand thermoplastics, you must first understand polymers, which are made up of linked chains of monomers. What separates one plastic from another is how those monomers are linked. Thermoplastics are characterized by weak links. What does this mean?

This property is what makes thermoplastics so versatile. Because of these weak links, thermoplastics can be heated, remolded, and cooled to resume a strong and rigid structure. In other words, thermoplastics could be recycled and reused indefinitely (barring the use of chemical additives intended to strengthen bonds, which can reduce their ability to be heat and remolded).

Thermosets, on the other hand, feature permanent chemical bonds that make for strong and durable products, but preclude the potential for heating and remolding the plastics, limiting recyclability.

Different Types Of Thermoplastics

Thermoplastics and thermosets are broad categories of plastics, and there are several types within each category. Some of the most common thermoplastics include:

• Acrylic
• Nylon
• Polyethylene
• Polypropylene
• Polytetrafluoroethylene (Teflon)
• Polyvinyl Chloride (PVC)

There are several other types, but these subcategories of thermoplastics are responsible for a wide range of familiar products. Acrylic, for example, can be used for windows, aquariums, and a variety of other purposes. Nylon is the basis for hosiery, carpet fiber, guitar strings, and more. Polyethylene is found in everything from milk containers to machine parts.

In Conclusion

Thermoplastics are all around us, in a variety of forms, and they can be made stronger and more permanent with the use of additives, although these modifications may impact the ability to recycle certain products.

When it comes to thermoplastics, you might not be clear on whether they can be recycled, as there is some confusion about the difference between thermoplastics and thermosets, especially when it comes to recycling. What’s the truth? Are thermoplastics recyclable, and how do they differ from thermosets?

Can Thermoplastics Be Recycled?

The simple answer is yes. Thermoplastics are a type of plastic that become soft when heated, so they can be molded, and then cooled to restore their rigid structure. Thermoplastics are frequently used to create items as diverse as pipes, insulators, adhesives, and more, and many of these products can be recycled and turned into new, usable products. What makes thermoplastics recyclable is that they can easily be reheated and remolded for new purposes.

The polymers found in thermoplastics are strong, but feature weak bonds. This is what allows them to be reused indefinitely, which is why these materials are highly recyclable. Different applications can cause plastics to downgrade when they are recycled, making them less recyclable with every phase of reuse, but this is typically related to additives, not the polymers themselves. Chemical additives are often designed to strengthen the bonds of thermoplastics, making them harder to melt and therefore limiting their potential for reuse.

The Difference Between Thermoplastics And Thermosets

There are essentially two main categories of plastics: thermoplastics and thermosets. What sets them apart? Primarily the way their polymers are linked. As noted above, thermoplastics feature weak bonds that allow for easy reheating and molding of the plastic.

Thermosets differ in that they feature permanent chemical bonds that cause them to retain their shape, even when reheated. This makes for strong products, but it is difficult to break down such plastics for the purposes of recycling and reuse. Thermosets cannot be heated and remolded like thermoplastics. They are brittle, but heat-resistant, which is why they’re frequently used for high-temperature applications, such as insulating materials.

The particular difference between thermoplastics and thermosets lies in the bonds linking polymers. In a sense, thermoplastic bonds could be described as ties that can be cut and retied, while thermoset bonds are more like a strong weld that is virtually unbreakable.

In Conlusion

Knowing which types of plastic can be recycled isn’t easy, and there are factors beyond the polymers themselves that can affect recyclability. One thing, though, is entirely clear: thermoplastics are recyclable. Thermosets cannot be recycled in the same ways, but this doesn’t necessarily preclude some form of reuse.

In the world of plastic manufacturing, everyday terminology is thrown around like confetti and it can be difficult to discern the nuances of specific processes. These processes are described by “plastic thermoforming,” “pressure forming,” and “vacuum forming.” All three are similar in scope, but there are important differences to understand. Employing the use of the wrong one in manufacturing could lead to disaster, and marketing an errant term can be equally troublesome. Let’s look closer at these common industry terms.

Plastic Thermoforming

This term has become a generic label applied to the plastic manufacturing process involving the heating of a thermoplastic sheet to a specific temperature and applying pressure to mold into a three-dimensional shape. When the plastic has cooled, it can then be trimmed and formed into its final product form. Thermoforming machines are large, highly-engineered and complex, and typically more expensive to purchase and operate.

Thermoforming is generally cost-effective and allows the freedom to accomplish whatever you need. In addition, the cooling time for the plastic is quick, making this a great choice when producing a high volume of quality products. Thermoforming and vacuum forming can both be used to create engaging decorative looks.

Vacuum Forming

Vacuum forming is a common thermoforming manufacturing process. Vacuum forming applies a vacuum energy to transform a heated plastic sheet into a pre-planned shape. The softened sheet in placed over a mold and then sucked down onto its surface. The sheet is then removed from the mold, cooled, and prepped for finishing. Vacuum forming allows more accurate replicating of the mold shape, which boosts the end quality.

Vacuum forming can be cheaper than thermoforming, due to lower operating machine costs. It is also a straightforward process that takes comparatively little time. Custom vacuum forming can also be tailored to suit specific needs and project parameters.

Advantages Of Thermoforming

Compared to related processes, such as injection molding, thermoforming boasts several key advantages:

• Lower tooling costs
• Shorter tooling lead time
• Efficient prototypes means faster product development
• Adaptive to evolving customer needs
• Integrated process with virtually limitless flexibility
• Wider design scope

Products Made Via Thermoforming

Many common products are made wholly or partly through the thermoforming process, including:

• RVs
• Pools and spas
• Fitness equipment
• Store displays
• Medical and office equipment
• Scientific instruments
• Control panels for an array of product
• Product housings and covers

In Conclusion

Thermoforming prepares your company to meet its particular market goals and, in the end, you can spend more time making product sales and less time waiting for it to clear the manufacturing steps.