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What is Thermoforming?

In thermoforming, pre-extruded plastic sheets or films are heated until they become pliable and are then shaped into a mold using vacuum, compressed air, or mechanical pressure.

This process is used to produce cups, trays, lids, and other thin-walled packaging items with high dimensional accuracy and consistent quality. Typical materials include polypropylene (PP), polystyrene (PS), and polyethylene terephthalate (PET). The heated sheet is stretched over or into a mold cavity, then cooled and trimmed to its final shape.

Thermoforming is an extremely efficient and resource-saving process, widely used in food packaging, transport trays, and disposable containers. It offers short cycle times, low tooling costs, and minimal material waste – ideal for high-volume packaging production.

Thermoforming – a highly efficient process for producing thin-walled plastic packaging. It is based on heating plastic sheets, which are then formed into shape using vacuum, compressed air or a mechanical plug. This method ensures consistent quality at high production speeds.

Phases of the Thermoforming Process

Phase Description Typical Parameters
1. Heating The plastic sheet is evenly heated to forming temperature. Temperature: 120–200 °C (depending on material)
2. Forming The softened sheet is drawn into the mold by vacuum, pressure, or plug assist. Forming pressure: 4–6 bar · Vacuum: 0.8–0.95 bar
3. Cooling The part solidifies and obtains its final geometry. Mold temperature: 15–30 °C · Time: 1–4 s
4. Demolding The formed part is released from the mold. Cycle time: 3–10 s (depending on sheet thickness)
5. Trimming The part is separated from the remaining sheet by punching or laser cutting. Cutting speed: 50–120 strokes/min

Typical Process Data (Example)

  • Material: PP, PET or PS
  • Sheet thickness: 0.3–1.2 mm
  • Heating temperature: 160–200 °C
  • Mold temperature: 20–30 °C
  • Cycle time: 4–8 s

Advantages of Thermoforming

Low material consumption, high production speed and low tooling costs. Ideal for cups, trays and containers with consistent quality and hygienic surfaces. Due to its efficient energy use, the process is among the most resource-saving forms of plastic processing.