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Twin Sheet ThermoformingTwin sheet thermoforming is a process that heats 2 separate sheets of plastic and welds them together to make a hollow part or product. It is able to create strong, lightweight, multi-dimensional housings and enclosures for electronics and hardware, panels that require thermal or acoustic insulation, and products like portable toilets, surfboards, doors and tables. There are many benefits to this method of thermoforming. It is quicker, produces perfect parts and creates stronger structures. The end product is lighter and cheaper than those produced via other methods. The electronic, health care and automotive industries often employ twin sheet thermoforming to produce their plastic parts.
The process of twin sheet thermoforming plastic parts, which are usually made of polycarbonate, a polycarbonate and ABS mix, or polyethylene, is quick and takes little labor. First, 2 sheets of plastic are each mounted on a separate frames and are placed into an oven to heat and become pliable. The first sheet is combined with cover-stock material using compression molding, and covers the bottom half of the mold. The second sheet is then vacuum formed on the upper half of the mold. The upper and lower mold halves are then pressed together, and the sheets are fused and sealed together into a single part. After drying and becoming rigid, the new part, which is hollow and looks similar to a blow-molded product, is then unloaded, trimmed and ready to be shipped.
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