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Introduction to Thermoformingand Vacuum Formingwww.mayfieldplastics.comSutton, MA 10590508.865.8150www.mayfieldplastics.comSutton, MA 10590508.865.81501

Introduction.3Pressure Forming.4Vacuum Forming.6Thermoforming Mold Making.8Table of ContentsPlastic Thermoforming orInjection Molding?.9Thermoforming orRotational Molding?.10Plastic Enclosures, Radomes &Other ThermoformingApplications.11Plastic Fabricationin Thermoforming.13Vacuum Forming FAQs.14Summary.16www.mayfieldplastics.comSutton, MA 10590508.865.81502

We are providing you with this white paper becausewe have learned that many people, includingengineers, often do not really understand plasticforming processes. Thermoforming is the formingof heated plastic on a mold to create a desired shape.Thermoforming, vacuum forming and pressureforming are considered thermoforming processes.Often confused with injection molding androtational-molding, thermoforming processes areunique and have distinct differences for a variety ofapplications. We hope the following guide clearlyexplains each of these processes, how they differ,and when they would be utilized.IntroductionThermoforming processes are used in a widevariety of applications like medical devices,fitness equipment, and electronic equipment.Thermoformed parts are used in automobilesand airplanes. Both modes of transportation usethermoformed parts for enhancing their interiors.Thermoforming produces custom plastic enclosuresthat are durable, cost-effective, high qualityand aesthetically appealing while offering closetolerances, tight specifications and sharp detail. Itoffers flexibility in tooling and engineering, and fastset-up, in the production of custom plastic parts.Thermoforming is usually the process of choicewhen producing large parts in quantities fromdozens to thousands. And, thermoforming isespecially helpful when producing prototypes. Inthis white paper report we will illustrate how eachprocess works and the advantages of each.If you have other questions, please contact MayfieldPlastics at 508.865.8150. or 800.339.3476.www.mayfieldplastics.comSutton, MA 10590508.865.81503

Pressure forming can achieve the high quality anddetailed look of injection molding, without theexpensive tooling costs. By using air pressure on theback side of the sheet during the forming process,textures, undercuts and injection molding detailscan be achieved. This is not usually possible withthe vacuum forming process.Pressure FormingMold makers start by creating a pattern basedupon drawings and specifications of the custompart. From the pattern, these craftsmen produceeither a hardwood or aluminum mold. A woodenmold is used mainly for a customer who requiresa prototype or a very low volume production run.An aluminum temperature controlled mold is usedfor a full production run and when the pressureforming process is required, temperature control ofthe mold is used to ensure repeatability.The pressure forming technique used by MayfieldPlastics provides for forming heavier sheet from0.063” thick up to 0.375” thick. The technique isaccomplished by forcing a hot sheet against a femalemold by introducing compressed air into the backside of the heated sheet while applying vacuum tothe tool side. This method will provide as much as75 psi working on the sheet surface, as compared tothe 14 psi in vacuum forming.www.mayfieldplastics.comSutton, MA 10590508.865.81504

Step 1Pressure FormingStep 2Step 3www.mayfieldplastics.comSutton, MA 10590508.865.81505

Vacuum forming is an economical process forproducing large sized, low volume parts at areasonable price. Vacuum forming involves thecontrolled heating of a thermoplastic material toa temperature where its shape may be heated toconform to the shape of the mold. The physicalchange to the pre-heated thermoplastic isaccomplished by the use of vacuum pressure.The advantages of vacuum forming are thecapability to form large parts without expensiveequipment and tooling. Vacuum forming allows forlarge production runs, and inexpensive mold anddesign modifications.Vacuum FormingThermoplastics most commonly specified areACRYLIC, ABS, HDPE, LPPE, PP, PVC, PETGand polycarbonates. Precolored sheets of someof these materials are also commonly used in thethermoforming of plastic parts.Secondary operations routinely used to producefinished parts include painting, pad printing, hotstamping and silk screening.www.mayfieldplastics.comSutton, MA 10590508.865.81506

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The quality of thermoformed plastics parts dependson the expertise used to produce the molds thatproduce exceptional plastic parts.Mayfield Plastics is one of the few thermoformingcompanies that controls all facets of mold makingin-house. Talented designers and machinists handmake the majority of our molds in-house. Thisprovides the ultimate control over quality, delivery,and part repeatability.Thermoforming MoldMakingThermoforming molds can be produced from a widevariety of materials, depending on the size of thepart, quantity, detail and accuracy. In some cases,molds may be made from wood or a combination ofwood and other materials in a “fabricated” assembly.As previously mentioned, these molds are craftedcompletely in our facility by experienced moldmakers, most of whom have been on the job for over30 years. They possess the prime characteristics offine craftsmen: talent and experience coupled withimmense pride in their work.www.mayfieldplastics.comSutton, MA 10590508.865.81508

In deciding between plastic thermoforming andinjection molding for your next project, there areseveral important factors to keep in mind:Tooling costs for thermoforming are significantlylower than tooling costs for injection molding.Thermoforming, particularly pressure forming, ismore cost effective for very large parts where thetooling costs would be prohibitive with injectionmolding. Despite pressure forming’s lower costs,nothing is sacrificed in terms of quality. Plasticthermoforming can achieve highly cosmetic finishesthat have an elegant look and that provide the lookand feel that meet the end user’s expectations.Plastic Thermoformingor Injection Molding?Thermoforming applications often also use paintingand secondary assembly in the production of valueadded parts. In the end, the best way to decidehow to proceed is with the assistance of a trusted,knowledgeable plastics processor.Mayfield Plastics’ engineering support staff can walkyou through the design and manufacturing of yourpart to ensure the best geometries and most efficientprocesses to meet your bottom line requirements.Mayfield Plastics has injection molding partners.We can recommend fine injection moldingcompanies to work with customers whose plasticforming needs are not suited to the thermoforming,pressure forming, and vacuum forming processesthat define our success.Put our plastic expertise to work for you—callMayfield Plastics at 800.339.3476 to begin theprocess.www.mayfieldplastics.comSutton, MA 10590508.865.81509

Rotational molding and thermoforming bothoffer advantages, depending on the type of projectat hand.The key advantages of thermoforming include: Sharp detail Tight tolerances Flexible tooling and engineering Efficient set-upRotational molding offers: The ability to mold multi-piece parts as one unit Consistent wall thickness Strong outside cornersThermoforming orRotational Molding?A well-trained, experienced plastics engineer canhelp you determine whether thermoforming orrotational molding is right for your project.Mayfield’s engineering support staff has theknowledge and expertise to help with these andother considerations, including: Material selection Improving geometries Concept development Final designIf rotational molding is the best fit, we can helpyou find the right rotational molder to meet yourproject requirements.www.mayfieldplastics.comSutton, MA 10590508.865.815010

Thermoforming can be used to manufacture anendless array of plastic enclosures, trays and othercomponents for a wide variety of markets. Scrollthrough the list below to get an idea of Mayfield’sown specialties in this area and then call us tosee how we can make the difference in your nextproject.Medical Equipment covers Sidewalls, user interface panels Bezels and enclosures Internal components Work-in-progress trays Hospital room panelsPlastic Enclosures,Radomes & OtherThermoformingApplicationsMayfield has extensive knowledge in manufacturinghigh quality heavy gauge plastic enclosures,thermoforming products and packaging for themedical industry.TelecomRadomes for: RVs Yachts Military aircraft Commercial aircraft Ground-based operationswww.mayfieldplastics.comSutton, MA 10590508.865.815011

We have significant thermoforming experience inthe production of all radome shapes and sizes.Industrial User interfaces Bezels Enclosures Plastic housings PanelsPlastic Enclosures,Radomes & OtherThermoformingApplicationsDiversified Bins, totes and bases Office furniture and interior panels Plastic enclosures for fitness equipment Underground pipe supports and housings Domes and panels for a variety of industries Marine vehicle parts Transportation components, plastic covers andenclosureswww.mayfieldplastics.comSutton, MA 10590508.865.815012

Heavy-gauge thermoforming provides thecapabilities to create a wide array of parts,including:Heavy-gauge Plastic enclosures Structural bezels Radomes Covers Equipment panelsPlastic Fabricationin ThermoformingThin-gauge Packaging Medical applications Work-in-progress trays Food containers Seedling traysPlastic fabrication in combination with heavygauge thermoforming provides additional valueby creating much larger parts while keeping toolingcosts down. CNC, heating and bending, and otherplastic fabrication processes can be combined tocreate a variety of diversified and complex plasticparts.Mayfield Plastics’ plastic fabrication expertise allowsus to create the end product that you need foryour next project. We also have the capabilities tothermoform materials from the thinnest plastic filmto sheets as thick as a half-inch.www.mayfieldplastics.comSutton, MA 10590508.865.815013

Vacuum forming, a low-cost thermoforming process,offers an economical method of creating largesize, low-volume plastic parts. Mayfield Plasticshas a half-century of thermoforming wisdomand expertise that you can rely on to answer yourthermoforming questions. Read through the mostfrequently asked questions below, or call us at800.339.3476 for more detailed answers.What size of parts can be vacuum formed?Mayfield has the capabilities to vacuum form partsas small as an ice cube to dimensions as largeas 8 feet by 5 feet. Any thermoplastics with theappropriate melt strength can be vacuum formed,and Mayfield Plastics’ dedicated staff has theexpertise and technical know-how to help you selectthe best material for your part.Vacuum FormingFAQsIs design and engineering assistance available formy vacuum-forming project?Yes. In fact, the high level of design and engineeringassistance available from Mayfield sets us apart fromother thermoforming companies. From conceptto final design, we can improve the geometries ofour customers’ products, ensuring a better part andbetter control over costs.What tolerances are required for radii and draftangles?The project’s specifics and geometries determinethese dimensions. Mayfield’s experienced engineeringsupport staff is available to help each customer workthrough the design process to make sure the finalvacuum-formed part is the right part for your project.www.mayfieldplastics.comSutton, MA 10590508.865.815014