THERMOFORMING | MATERIALS
Recent advances in thermoforming include wood-based formable film, new materials for food packaging and several forthcoming live machinery demonstrations at K2025
Pressing business: latest in thermoforming technology
Thermoforming continues to gain ground as a processing technique – with new applications including food packaging and medical products. In one example, a cover for a medical cart has won the top prize at the Society of Plastics Engineers (SPE) thermoforming division’s conference. The component, from Profile Plastics, was made using multi-part pressure forming for a new medical cart. Six panels cover one cart of a two-cart system used for a non-invasive tumour treatment procedure. The cart also includes four vacuum-formed parts. It used 0.187in- and 0.250in-thick PVC/acrylic
material with custom, moulded-in colour and a temperature-controlled aluminium tool with negative cavity. There were two main challenges: achieving a cosmetic appearance while using no visible fasteners; and incorporating sufficient air flow. The original design was intended for injection moulding. PVC blocks along the edges provided panel-to-panel alignment and mating for a tight- fittng, clean transition between parts. Wall thickness at the edges was adjusted via CNC for better mating. The design also included an intricate vent pattern to meet the air flow requirements. Vents with proper draft and spacing were formed-in and back-shaved,
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so there were no cutter marks on the A side. The customer also needed a magnetic field in
two locations to hold tools during use. The design included developing attachment points for magnets, determining proper magnetic field strength and controlling material thickness to prevent interference. California-based Ray Products won two awards
– for parts made for electric vehicle and battery applications.
One was a cover for an EV charging station, which needed to meet stringent outdoor require- ments while providing a cosmetic finish without paint. The customer previously other methods such as injection moulding and even sheet metal for its equipment covers. These parts typically failed to meet the outdoor requirements or required secondary finishing processes. Pressure formed acrylic/PVC was the solution for
a durable, weather-resistant enclosure. The final 11-part enclosure was engineered for easy assem- bly with minimal attachment points, eliminating the need for secondary processes. Using pressure forming, several thousand units with consistent quality and part-to-part repeatability were made. The second part was a low-speed EV door
September 2025 | FILM & SHEET EXTRUSION 13
Main image: Sulapac Prime thermoforms at lower tempera- ture, which can save up to 20% in energy
IMAGE: PRIMEX
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