Thermoforming is a process that allows the creation of customized and versatile products by utilizing the potential of molded plastic materials. This technique, widely used by industry leaders like Unigasket, offers an effective alternative to traditional injection molding. Thermoforming is particularly useful when there is a need to reduce equipment costs and produce a low number of items. It is also recommended when using coextruded materials, which are composed of different layers, and when thin wall thickness is required.
One of the benefits of thermoforming is its remarkable production flexibility, allowing the production of different batches of parts. Unlike injection molding, thermoforming can print very thin thicknesses. With injection molding, the liquid plastic cannot be channeled far from the injection point and cannot fill the entire mold before it cools.
Thermoforming is considered a secondary transformation technology as it works on semi-finished products such as sheets and films, rather than powdered or granular materials. The process involves printing plastic materials from coils or sheets, either under vacuum or under pressure. In the first case, the plastic film adheres to the mold walls by applying strong external air pressure, which also aids in cooling. In the second case, the hot plastic material adheres to the mold through vacuum suction, allowing it to accurately reproduce the mold shape, even in intricate details.
Various polymers can be processed using thermoforming, including expanded PE, PET, PVC, and SAN. The obtained products can undergo additional treatments such as embossing, glittering, or metallization. Thermoforming finds applications in various industries such as furniture, construction, marine, electrical and electronic, medical, food packaging, and transportation.
Thermoforming is becoming increasingly popular due to its ability to produce a wide variety of products in different sectors. Its production flexibility is cost-effective, especially for small production runs, as mold replacement times are quick.
Thermoplastic polymers, once cooled, retain their molecular structure and can be reheated and reworked. These materials are resistant and lightweight, making them suitable for applications where weight is a potential concern. The melting and resolidification capability of thermoplastics allows them to be easily shaped into various forms. They can be customized and modified with additives to enhance properties such as weather resistance, thermal conductivity, and chemical resistance. Additionally, the cost-effectiveness of thermoplastic production is lower compared to other materials. However, it is important to note that some polymers are susceptible to environmental pollution and may have limitations regarding temperature resistance.
In the mechatronics field, thermoplastic polymers are used to produce components for robotics and electronic devices due to their lightweight and electrical insulation properties. In the construction industry, they are used for hydraulic system pipes, energy-efficient windows, and flooring coatings. Thermoplastic polymers are also suitable for fluid handling applications, such as fittings, pipes, and valves, as they are chemically inert and corrosion-resistant. In the electromedical field, thermoforming is employed to produce diagnostic equipment, imaging devices, and medical instruments that require biocompatible materials.
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