How portable product design uses twin sheet and pressure forming

Achieving complex geometries and superior aesthetics within cost constraints

Twin-sheet formed secure container top panel

An OEM recently had Profile Plastics make parts for a portable machine that had to be durable enough for heavy use in a public environment. Profile’s twin sheet forming delivers the ability to create cost-effective plastic parts with complex geometries and high aesthetics.

The successful NPD project shows how thermoforming performs within tight budgets.

Project Overview

A US-based manufacturer was developing a new collapsible container system for collecting materials at large public events. Main drivers for the product were security, simplicity, and easy transportability.

Designers wanted to try thermoforming to produce several system components, since it is known to produce light and strong parts with high surface quality. However, they had no experience with the process.

They asked Profile to review initial concepts. Four different components were found to be suitable for thermoforming. In particular, the top deck and the front door were ideal for twin-sheet forming. Good candidates for pressure forming included the cover and bin.

Challenge: Provide high aesthetics while keeping costs low

Controlling production costs on this project was vital for the customer. The system required light weight and high security. Some competing products used folding cardboard to be lightweight but offered weak security. Rotomolded products were more secure but large and heavy.

Twin sheet forming delivers strong and light hollow parts. Designers liked how it offers more value than blow molding and better tolerances than rotomolding, the other plastic processes they considered.

At the same time, aesthetics mattered. The parts needed to be attractive and rugged to project a sense of security. Brass inserts for bolts on the top deck would help make the assembly tamper-proof.

Solution: DFM and material expertise hold the line

Early engagement with Profile’s engineering team resulted in the design being purchase-ready when the OEM needed initial launch prototypes. Fit and function in the final product were verified using 3D printed samples.

The collaboration gave the customer confidence to go directly to production tooling when the project was ready, which reduced costs. Design For Manufacturing (DFM) engineering created parts that could meet functionality and manufacturing process requirements in just six months.

The project also needed a rigid material durable enough to hold up during shipping and times of heavy use by the public. The customer chose ABS plastic for its impact strength.

Using the same starting gauge, or thickness, for all four parts saved cost in the material purchases. An acid-etched texture on the tooling ensured that the single-sided pressure formed parts and twin sheet parts had a consistent appearance.

Results: Strategic sampling build up to production run

DFM kept the project on track for the OEM. Once the design was settled, Profile’s operations team developed a strategic sampling plan. This ensured delivery dates were met while confirming product functionality before any large manufacturing runs. Final annual production would number in the low thousands.

Profile’s engineering, material expertise, and quality control helped create a successful on-time launch for a first-time customer in a unique yet highly public-facing market.