Smart Thermoforming for Superior Packaging

Thermoforming is a manufacturing process in which plastic sheets are heated until pliable and then formed over precision molds to create custom shapes. Once formed, the parts are trimmed and finished to meet exact dimensional and functional requirements. This process is widely used for producing trays, blisters, and protective packaging due to its efficiency, design flexibility, and material consistency.

THERMOFORMING PROCESS

HEAT | FORM | COOL | TRIM | PACK

In the thermoforming process of product design, it all begins with the initial design concept. Once a product is determined, designers create three-dimensional models for thermoforming the desired items. Both designers and engineers utilize Computer-Aided Design (CAD) software to develop digital representations of the product and evaluate how the plastic sheet will behave during the thermoforming process.

The role of 3D modeling in thermoforming product design is crucial, as it simplifies and enhances the design process. Our implementation of CAD software has led to significant advancements in product design. One of the key steps in designing thermoformed products in CAD is creating a 3D model that considers the material properties and production constraints.

MOLD DESIGNING

Tooling for thermoforming refers to the various molds, 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 molds. A male mold, 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 mold, 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.

TOOL DEVELOPMENT

Interchangeable inserts can be added to molds to accommodate changes in product dimensions. Different types of tooling are essential for designing and manufacturing high-quality thermoformed products.

The tool is designed for easy removal of the formed part, typically achieved through the use of draft angles and fillets. Properly designing the tooling for thermoforming is crucial to producing parts with high quality, consistent accuracy, and repeatability.

To ensure the longevity and quality of the molds, we create aluminum molds that enable efficient and cost-effective production of high-quality products. This process involves several steps, including designing, machining, and finishing the mold. We pay careful attention to detail by using CNC machining techniques to achieve accuracy and tight tolerances in shape.Interchangeable inserts can be added to molds to accommodate changes in product dimensions. Different types of tooling are essential for designing and manufacturing high-quality thermoformed products.

The tool is designed for easy removal of the formed part, typically achieved through the use of draft angles and fillets. Properly designing the tooling for thermoforming is crucial to producing parts with high quality, consistent accuracy, and repeatability.

To ensure the longevity and quality of the molds, we create aluminum molds that enable efficient and cost-effective production of high-quality products. This process involves several steps, including designing, machining, and finishing the mold. We pay careful attention to detail by using CNC machining techniques to achieve accuracy and tight tolerances in shape.

When selecting materials for thermoforming products, several important factors must be considered. First, the chosen material should have a high melting point to endure the heat required for the thermoforming process. It must also maintain its structural integrity during and after forming, while possessing the desired physical and aesthetic qualities for the specific product being produced.

Common materials used in thermoforming include thermoplastics such as polystyrene, polyethylene, and polypropylene. Each of these materials has unique characteristics and advantages, so careful consideration is necessary to ensure the right choice for the intended application.

Additionally, the cost-effectiveness of the material is an important factor, along with any environmental concerns related to its production and disposal. Ultimately, selecting the appropriate material for thermoforming is a crucial part of the product design process. This careful selection is key to successfully creating a high-quality and effective product.

Material Selection

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 mold. Then shape it into the mold 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 mold, forcing them together.

THERMOFORMING PROCESS

During pressure forming, pressurized air pushes the plastic into the mold. 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 mold, it's cooled and removed from the mold, retaining its final shape.

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.

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.

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.

CUTTING / TRIMMING

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.

SAFE PACKING

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.

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.

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 ASSURANCE

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.

CUSTOMER SUPPORT