Thick Gauge Custom Thermoforming
(From 2mm to 10mm Thicknesses)

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Thick gauge thermoforming is employed in various industries to manufacture robust and durable plastic components with increased material thickness. Here are in-depth applications of thick gauge thermoforming across different sectors:

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1. Automotive Components:
   - Interior Trim Panels: Thick gauge thermoforming is used to produce heavy-duty interior trim panels for automotive applications, providing durability and impact resistance.
   - Exterior Body Panels: Large exterior body panels, such as truck bed liners and mud flaps, are often manufactured using thick gauge thermoforming for increased strength and toughness.

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2. Heavy-Duty Industrial Parts:
   - Machine Housings: Thick gauge thermoforming is utilised to produce robust housings for industrial machinery, providing protection and structural support.
   - Equipment Enclosures: Thick gauge thermoforming is suitable for manufacturing enclosures for heavy-duty equipment used in construction, agriculture, and manufacturing.

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3. Medical Equipment:
   - Durable Housings: In the medical industry, thick gauge thermoforming is applied to create sturdy housings and enclosures for medical equipment that require a higher level of impact resistance and durability.

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4. Outdoor and Recreational Products:
   - Recreational Vehicle Components: Thick gauge thermoforming is used to manufacture components for recreational vehicles, including durable exterior panels, fender skirts, and storage compartments.
   - Outdoor Furniture: Robust and weather-resistant outdoor furniture components, such as benches and table tops, can be produced using thick gauge thermoforming.

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5. Large Displays and Signage:
   - Trade Show Displays: Thick gauge thermoforming is employed to create large and visually striking displays for trade shows and exhibitions, where durability and visual impact are essential.
   - Outdoor Signage: Durable and weather-resistant outdoor signage, such as billboards and informational signs, can be produced using thick gauge thermoforming.

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6. Consumer Durables:
   - Large Appliance Housings: Thick gauge thermoforming is utilised to manufacture housings for large appliances like washing machines and refrigerators, providing structural integrity and impact resistance.
   - Ruggedised Electronic Housings: Electronic devices that require robust and impact-resistant housings, such as industrial control panels, can benefit from thick gauge thermoforming.

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7. Construction Components:
   - Architectural Panels: Thick gauge thermoforming can be used to produce architectural panels for both interior and exterior applications, providing a combination of durability and design flexibility.
   - Cladding and Trim: Durable cladding and trim components for construction projects, offering impact resistance and weather-ability, can be produced using thick gauge thermoforming.

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8. Aerospace Applications:
   - Structural Components: In aerospace, thick gauge thermoforming is applied to manufacture structural components that require a balance of strength and lightweight characteristics.
   - Interior Panels: Durable interior panels for aircraft, providing impact resistance and durability, can be produced through thick gauge thermoforming.

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Here are the key features and considerations associated with thick gauge thermoforming:

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Process Overview:

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1. Material Selection:

   • Thick gauge thermoforming often involves using heavier and more rigid thermoplastic materials compared to thin gauge thermoforming. Common materials include high-impact polystyrene (HIPS), ABS (acrylonitrile butadiene styrene), and polycarbonate.

2. Sheet Heating:

   • The thermoplastic sheet is heated to its forming temperature, which is higher than in thin gauge thermoforming due to the increased thickness of the material.

3. Clamping:

   • The heated sheet is clamped into a frame or mold using vacuum or mechanical methods to maintain the desired shape during the forming process.

4. Forming:

   • The heated and clamped sheet is then forced into or onto a mold using vacuum pressure or mechanical means. The mold imparts the desired shape to the thick plastic sheet.

5. Cooling:

   • Cooling is crucial to solidify and maintain the formed shape. The thicker material requires careful temperature control to prevent warping or distortion during the cooling process.

6. Trimming:

   • Excess material is trimmed away after forming to achieve the final product. This may involve more robust trimming equipment due to the increased thickness of the material.