Thermoforming Process

Thermoforming is a highly effective technique for transforming flat plastic sheets into three-dimensional forms. By uniformly heating the plastic, it becomes pliable enough to be molded either through vacuum deep drawing or by using a closed mold with a press. This process is ideal for creating durable, permanently reshaped plastic components.

How Thermoforming Works

Thermoplastics, when heated, soften to the point where they can be easily molded into new shapes. To ensure the material’s flexibility before forming, it can be heated either entirely or partially using hot air or infrared radiation, depending on the specific requirements of the application.

Deep drawing with hot air

In the deep drawing process, Leister air heaters and hot air blowers are used to precisely heat the plastic material before it is formed. Leister’s extensive range of equipment allows you to select the most suitable tools for your specific process, ensuring optimal results.

Deburring, a related forming process, involves removing fine, unwanted burrs from injection-molded plastic components. By applying hot air, these burrs are melted and reshaped through surface tension, leaving a smooth finish. Additionally, hot air can be used to separate plastic parts connected by narrow webs after the injection or blow molding process, providing a clean and efficient separation.

Deep drawing with infrared

When deep drawing with infrared, the material is heated using infrared radiation, which is particularly efficient and precise. Leister’s KRELUS infrared heaters offer rapid response times, allowing them to be turned off during non-productive periods, resulting in significant energy savings—especially beneficial for sequential processes.

In the automotive industry and beyond, thermoforming is commonly used to produce molded parts from plastic rolls or sheets. Items such as door panels and parcel shelves are frequently created through this process. For plastics with a thickness of 1 mm or more, KRELUS infrared heating sources are the preferred choice, providing precise and efficient heat application.

The Thermoforming Process

The thermoforming process itself follows these straightforward steps:

Insert the Plastic
The plastic sheet or roll is positioned in the thermoforming machine.
Heating
The material is uniformly heated using hot air or infrared radiation until it becomes pliable.
Forming
The softened plastic is then molded into the desired shape using vacuum deep drawing or a press.
Cooling
The newly formed part is cooled and solidified, maintaining its new shape.

The key advantage of using infrared heating in this process is its ability to deliver precise, controlled heat, ensuring energy efficiency and superior product quality.

Leister’s advanced thermoforming solutions provide the tools and technology needed for efficient, high-quality plastic forming, making them ideal for a wide range of industrial applications.