Design Choices to Reduce Thermoforming Costs

Simplifying Part Geometry & Radii

Why Geometry Simplicity Matters

For high-volume production, optimized geometry must align with multi-cavity tooling design to ensure consistent forming across all parts.
Simplified geometry also plays a key role in reducing secondary operations, minimizing the need for trimming, drilling, and post-processing.

In thermoforming and plastic part manufacturing, complexity is the silent cost driver. Intricate geometries, sharp transitions, and inconsistent radii increase tooling difficulty, reduce forming consistency, and elevate rejection rates.

At HIPLEX, we engineer parts with manufacturability-first thinking—simplifying geometry without compromising function or aesthetics.

The Problem with Complex Geometry

Overly complex designs often lead to:

• Uneven material distribution

• Thinning at critical stress points

• Difficulty in mold release

• Increased cycle time

• Higher tooling and maintenance costs

Sharp internal corners and abrupt transitions are especially problematic, as they restrict material flow during forming.

The Role of Radii in Thermoforming

Proper radii design directly supports wall thickness optimization by enabling uniform material distribution during forming.
Radii are not just aesthetic — they are critical to performance and manufacturability.

Draft Angles Link:

Smooth transitions combined with proper draft angles ensure easy mold release and reduce surface defects.

Best practices:

• Avoid sharp corners wherever possible

• Maintain uniform radii across transitions

• Use larger internal radii to support smooth material flow

• Ensure radii are proportional to sheet thickness

Well-designed radii:

• Improve structural strength

• Reduce stress concentration

• Enable consistent wall thickness

• Extend mold life

HIPLEX Design Approach

We apply a structured design optimization process:

1. Geometry Simplification

• Eliminate unnecessary features

• Combine surfaces where possible

• Reduce deep, narrow sections

2. Radii Optimization

• Standardize corner radii

• Smooth transitions between surfaces

• Ensure tool-friendly curvature

3. Manufacturing Alignment

• Design for uniform forming behavior

• Minimize undercuts and sharp edges

• Improve part release efficiency

Before vs After Optimization

Before:

• Sharp internal corners

• Uneven thickness zones

• High stress concentration

After HIPLEX Optimization:

• Smooth radii transitions

• Balanced material distribution

• Improved durability and finish

Key Benefits

• Faster production cycles

• Reduced rejection rates

• Lower tooling wear

• Enhanced part strength

• Consistent visual quality

Design Guideline Snapshot

• Minimum internal radius: ≥ 1.5× material thickness

• Prefer gradual transitions over abrupt changes

• Avoid zero-draft vertical walls

• Maintain symmetry where possible

Conclusion

Simplifying geometry and optimizing radii is not just a design choice — it’s a manufacturing advantage. With HIPLEX, every curve and transition is engineered for performance, efficiency, and reliability.

Explore Complete Design Guidelines

Explore our complete Thermoforming Design Guidelines to understand how geometry, tooling, and process optimization work together to deliver consistent, high-quality production.