Thermo
forming

Forming your Ideas!

Process of Thermoforming

Thermoforming is a manufacturing process that involves heating a sheet of thermoplastic material to its softening point and then stretching it over a mould to achieve the desired shape. Once the material has cooled and solidified, it is trimmed to the correct size and shape and ready for use.

Designing

In the thermoforming process of product designing, of course, yes! It starts from the design. Once the product is decided, the designer creates three-dimensional objects for thermoforming the desired products. Designers and engineers use Computer-Aided Design (CAD) software to create digital models of the product and assess how the plastic sheet will react during the thermoforming process. The importance of 3D modeling in thermoforming product design makes design easier and more efficient.

We have made multiple advancements in product design by implementing computer-aided design (CAD) software. Making a 3D product model that takes
into account the material qualities and production limitations is one of the key steps in the design of thermoforming products in CAD.

To make sure that the product design can be properly manufactured in the desired shape and size, it is studied and simulated in the program. Additionally, speedy and effective design iterations enable us to optimize the design for reduced time and expense throughout the production phase. We provide overall client happiness and higher performance.

Material Selection

When it comes to material selection for thermoforming products, there are several factors to consider. Firstly, the chosen material must have a high enough melting point to withstand the heat required for the thermoforming process. Additionally, it must be able to maintain its structural integrity during and after forming and possess the desired physical and aesthetic properties for the particular product being produced. Common materials for thermoforming products include thermoplastics such as polystyrene, polyethylene, and polypropylene. Each material has its unique characteristics and benefits, and careful consideration must be taken to ensure the right choice is made for the intended application.

Tooling

Tooling for thermoforming refers to the various moulds, dies, and fixtures used to shape and form the plastic material during the manufacturing process. These tools are precise and highly engineered, and their design is crucial to the quality and consistency of the final product. However, for the process to be successful, the use of specialized tooling is essential.

Two major types of tooling used in thermoforming are male and female moulds. A male mould, also known as a plug, is a positive replica of the final product; it is placed on top of a sheet of plastic and pressed down with a vacuum to form the desired shape. A female mould, on the other hand, is a negative replica that is used to create a concave space where the plastic sheet is heated and drawn into the desired shape. Additionally, interchangeable inserts can be added to moulds to accommodate changes in product dimensions. As we understand, the different types of tooling are crucial in designing and manufacturing high-quality thermoformed products.

Thermoforming

A thermoplastic sheet is fed into a heating device; to raise the temperature of the plastic, the heater harnesses the power of electricity. The plastic remains in the heater until it becomes pliable and soft. The time it takes and the temperature selected for this to happen depend on the properties of the plastic being used. Regardless, once pliable, the plastic is moved over to the form station, where it is stretched over a temperature-controlled surface known as a mould. Then shape it into the mould using vacuum forming, pressure forming, or a combination of both. Using a vacuum, pressure forms, and a vacuum suctions the air between the plastic and the mould, forcing them together. During pressure forming, pressurized air pushes the plastic into the mould. Of the two, pressure forming yields the best level of adherence and is preferred for detail-heavy applications Once the material has been formed in the mould, it’s cooled and removed from the mould, retaining its final shape.

Trimming

We achieve process optimization by lowering draft angles, reducing sharp edges, and minimizing undercuts. Furthermore, careful material selection must meet design specifications and prevent potential problems with thermoforming. Taking into account the material's thickness, which will have an impact on the material's ability to be formed and the quality of the finished product. Validating that the design is workable, complies with the specifications, and produces the desired result. The design of the prototype should be based on the specific needs and requirements of the client. The goal is to create a functional, visually appealing, and cost-effective product.

The tool is designed to allow for easy removal of the formed part. This is typically accomplished through the use of draft angles and fillets. By designing the tooling properly for thermoforming, it is crucial to achieve high-quality parts with consistent accuracy and repeatability.

To ensure the longevity and quality of moulds, we craft aluminum moulds by enabling efficient and cost-effective production of high-quality products. Involving several steps, including designing, machining, and finishing the mould, by giving careful attention to precise detail by using CNC machining techniques for accuracy and shape with very tight tolerances.

The thermoformed products need to be trimmed in the majority of operations. By using hydraulic cutting and punching machines, trimming helps form objects to the desired dimensions and removes extra material. Numerous technological parameters are available for hydraulic cutting machines, which are renowned for their great performance, sturdiness, extended functional life, and user-friendly operations. These hydraulic cutting machines, which can be operated manually or electrically, are used for trimming and shaping skin-packed and vacuum-formed goods. They use uniformly simple and straight steel blades.

Packing

The Greatest Safeguarding and Display
Safe packaging is a crucial step in the design process of any product. Until the product reaches the customers, both that and the packaging procedure must be safe and secure. Despite this, Hiplex Technologies packs with extreme caution, making sure that food-related products are packed with the utmost care, cleanliness, and safety.

Sales Boost Solution
The ideal packaging presents the best possible image, is economical, and is most suited for logistical processes. When combined properly, that can lead to higher sales—especially if it's reasonably priced!

Fast Turnaround
Hiplex Technologies is well aware that speed and adaptability are key components of food service. For this reason, we were built to be flexible and offer the appropriate answer at every given moment. That's how we relieve our clients' burdens!

Creative and Enticing
The markets for convenience and food service are always changing. Innovative, progressively appealing packaging is needed to meet evolving consumer preferences and emerging trends. We translate advances that our trend watchers observe into creative solutions that are visually appealing and unique.

Thermoforming is a fairly inexpensive procedure, used to the benefit of industries including cosmetics, sports and recreation, food processing, healthcare, entertainment, electronics, appliances, textiles, toys, and office supplies. Thermoforming is valued in packaging and shipping in particular, because it allows them to quickly and economically receive products they rely on, like shrink wrap, bins, clamshells and blister packs.

Furthermore, the cost-effectiveness of the material must also be taken into account, as well as any environmental concerns associated with its production and disposal. Ultimately, selecting the appropriate material for thermoforming products is a crucial aspect of the product design process and should be carefully considered, ensuring the successful creation of a high-quality and effective product.

By incorporating advanced control systems, they improve operational accuracy and minimize waste, ultimately leading to enhanced productivity and cost-effectiveness in the production process. Their versatility renders them suitable for a range of applications, from packaging to automotive components, highlighting their importance in contemporary manufacturing workflows.

Quality Assurance

Client satisfaction: We pride ourselves on offering high-quality safe, secure, and efficient goods and services.

Commitment: We pledge to meet our quality goals of operating efficiency, customer satisfaction, and on-time delivery.

Compliance: We proactively evaluate and conform to the constantly changing regulatory standards that direct the markets and areas we service.

Enhancement: Our goal is to consistently raise the caliber of our services, goods, and quality management system (QMS).

Quality is essential when it comes to plastic trays. Your chosen partner should have strict quality control procedures in place. At Hiplex Technologies Plastic Trays, we take quality very seriously. Our trays are rigorously tested to guarantee they meet the highest requirements. We focus on quality from material selection to manufacturing methods at every stage.

Exceptional customer service is another important consideration. Your partner should remain receptive and responsive towards your requirements during the process. Hiplex Trays takes pride in providing personalized service and exceptional customer support. We are here to help you from the first consultation to the delivery of your customized trays.