【Pressure Forming】Explore Diverse Thermoforming Applications: Product Development, Industry Trends at a Glance
📚 Table of Contents
Thermoforming during product development
Automotive and Transport
Medical devices and equipment
Packaging and Display
Electrical and Electronic Equipment
Consumer Goods
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 thermoplastic material to a pliable state and then molding it into the desired shape. Common applications include packaging, prototyping, food and beverage containers, and small-batch production.
In this guide, we will explore some trending thermoforming applications, divided into three categories:
As consumers, we typically only see thermoforming in the final parts we use every day. However, thermoforming is commonly used throughout the product development process.
There are three main stages where thermoforming can be used:
1. Rapid Prototyping
This process is used to evaluate the function 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 Jigs
Thermoforming can be used to manufacture tools for producing other products. For example, clear jigs made using 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 Transport
Thermoforming is widely used in the automotive and transport industries to produce interior and exterior parts. These parts are made from materials like ABS, which can withstand high temperatures and pressure.
• Automotive Interior Components
Dashboards, door panels, and armrests
• Automotive Exterior Components
Bumpers, spoilers, and fenders
• Recreational Vehicle Components
RVs, campers, 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 automotive parts made with Mayku Multiplier
Medical Devices and Equipment
Thermoforming is an ideal process for manufacturing medical devices and equipment. It can provide sterilizable, durable, lightweight, and precise parts.
• 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 Mayku Multiplier pressure forming machine (Source: Oertli)
Packaging and Display
Thermoforming is widely used in the packaging and display industries. These parts are typically made from materials such as 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 Mayku Multiplier
Electrical and Electronic Equipment
Thermoforming is an ideal solution for producing electrical and electronic components. It provides lightweight, strong, and heat-resistant parts with precision and consistency.
• Computer Casings
Desktop computers and laptops, switch boxes, control panels, and junction boxes
• Protective Casings
Laptops, measuring equipment, and cameras
• Refrigeration Components
Door panels and inner liners
Computer mouse prototype made with Mayku Multiplier using HIPS
Consumer Goods
Thermoforming is a cost-effective method for producing 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
• Sports Equipment
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 the possibilities to designers and manufacturers.
Beta chose to design three consumer electronic products - a mechanical keyboard housing, a mouse, and a webcam, to demonstrate how fine and detailed parts made with the Multiplier can be. These products are designed for "users" with customizable housings that can be quickly swapped and replicated to test different textures and finishes.
Freeform Prototyping
Beta uses a combination of 3D printing and pressure forming molds for product prototyping. Each mold takes less than five minutes to make and is ready to use. The Multiplier can capture intricate surface details, making it an excellent tool for experimenting with textures in molds.
Color, Material, Finish
Beta uses different CMF (Color, Material, Finish) effects to highlight the Multiplier's capabilities for makers and designers.
The Multiplier allows creators to quickly test ideas without outsourcing; keeping costs low and creativity flowing by using various sheet materials.
Rapid, affordable 2mm molds can be tested instantly on the same machine before moving to flexible molds or selecting 5mm+ sheets for injection molding quality enclosures.
Rapid, affordable 2mm molds can be tested instantly on the same machine before moving to flexible molds or selecting 5mm+ sheets for injection molding quality enclosures.
Shorten Lead Times
Outsourcing custom mold design or prototype parts can be a lengthy process. Going back and forth on design drafts and then waiting up to 12 weeks for molds or parts 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 improve business sales potential and higher productivity.
►Learn more about thermoforming technology? Please refer to our Mayku guide:
【Thermoforming Application】Vacuum Forming V.S. 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 Forming Machine
• FormBox Desktop Vacuum Forming Machine
References
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