CAPABILITIES
Optimize part performance and cost with our material expertise
The ideal material for your part will meet your performance specifications and be as cost-effective as possible.
Many criteria may be applicable depending on the part requirements, including custom color, flammability rating, impact strength, heat deflection temperature, ROHS/REACH certification, etc. But identifying material options can be a challenge.
Profile Plastics regularly provides guidance to help customers make smart material choices.
Options to meet your performance specifications and budget
Customers benefit from having a wide range of options. We work with an array of materials.
Thermoforming materials are supplied as plastic sheets in a wide variety of polymers, including blended materials. For design engineers, material selection is a key but complex consideration since so many options are available.
With 65 years of experience, we can help you pick the right plastic for your project. Use our Thermoforming Materials Selection Guide to start. For complete part design information, download our Thermoforming Design Guide.
In the toggle sections below, you’ll find a description of various thermoforming materials along with their advantages, disadvantages, and applications.
ABS – Acrylonitrile Butadiene Styrene
Acrylonitrile butadiene styrene (ABS) has good impact strength and is both rigid and abrasion resistant. This cost-effective thermoforming material also provides good chemical resistance, works well in high-temperature environments, and withstands moisture.
Among its disadvantages, ABS is sensitive to ultraviolet light (UV); however, a UV-protective cap layer can be applied to ABS sheets that need to withstand extended exposure to the sun’s rays. Applications for thermoformed ABS products include equipment enclosures.
HIPS – High Impact Polystyrene
High impact polystyrene (HIPS) is inexpensive and comes in many colors. This thermoplastic material is hard, stiff, and has good impact characteristics in impact-modified versions. HIPS also has good electrical insulating properties, which makes it suitable for electronic enclosures.
Compared to ABS, HIPS is more brittle and provides marginal resistance to cracking and breaking. HIPS is generally unfit for outdoor use, but weatherable grades are available. Applications include medical trays and electrical insulation.
PE - Polyethylene
Polyethylene (PE) is flexible and electrically insulating. It also provides broad chemical resistance, has good impact strength, and is water resistant. For outdoor applications, PE can contain additives that impart UV resistance.
Polyethylene has cosmetic deficiencies, however, and its high rate of shrinkage means that this thermoforming material is not ideal for parts with tight dimensional tolerances. Typically, thermoformed PE is used for lids, drums, storage contains, crates, pallets, and truck bed liners.
HDPE - High-Density Polyethylene
High density polyethylene (HDPE) resists impact and cold temperatures. It’s also cost-effective and dishwasher safe. Because it’s non-leaching, HDPE will not transfer chemicals, which makes it an excellent choice for food and beverage containers.
Among its disadvantages, HDPE is less dimensionally stable than other thermoforming materials. It provides poor UV resistance and is sensitive to stress cracking. Although HDPE resists solvents, it does not resist oxidizing acids. HDPE thermoformed products include storage sheds.
HMWPE - High-Molecular Weight Polyethylene
High-molecular weight polyethylene (HMWPE) is similar to HDPE but offers greater resistance to acids and alkalis. In addition to excellent chemical resistance, this thermoforming material has high impact strength and high abrasion resistance.
The main disadvantage of HMWPE is its high cost. However, this premium-grade engineering plastic can be thermoformed into material handling products such as shipping trays, containers, chutes, and bins. It’s also used in fender systems for automotive and marine applications.
PVC - Polyvinyl Chloride
Polyvinyl chloride (PVC) is inherently flame-retardant. This thermoforming material also resists staining and has good impact strength at room temperature. In addition, PVC resists wear, tear, shock, abrasion, and corrosion.
PVC is difficult to process, however, and this thermoplastic can experience a significant reduction in material properties over time. Because PVC is lightweight and cost-effective, thermoforming applications include shower curtains.
PET - Polyethylene Terephthalate
Polyethylene terephthalate (PET) has a high strength-to-weight ratio and is shatterproof. It’s also lightweight, electrically insulating, and has low gas permeability. Because it won’t react with water, PET plastic is sometimes used in food-contact applications.
The main disadvantage of PET is that it has a lower heat resistance than other polymers. Although it’s free from BPA and phthalates, PET can degrade the taste of food and beverages that are stored for extended periods of time. PET thermoforming applications include packaging trays.
PETG - Polyethylene Terephthalate Glycol
Polyethylene terephthalate glycol (PETG) is clear, easy to process, and resists impact and chemicals. It also has a deep draw, the process of stretching a plastic sheet into a three-dimensional shape with a significant depth relative to the part’s width and length.
PETG has better heat resistance than PET and is less prone to crystallization. PETG is not UV-stable, however, and this makes it unsuitable for extended exposure to sunlight. Applications for PET thermoforming include medical trays and totes, displays, machine guards, and housings.
Acrylic - Polymethyl Methacrylate (PMMA)
Polymethyl methacrylate (PMMA) is better known as acrylic, and Plexiglas® is a common tradename. Normally, acrylic is clear; however, PMMA also comes in a variety of colors. This thermoforming material also resists abrasion and offers good UV protection. Impact-resistant grades are available.
Acrylic weights approximately 50% less than glass but it’s also more prone to scratching. Disadvantages include a lack of heat resistance. If this thermoplastic breaks, jagged edges result. Applications for acrylic or PMMA include skylights, windows, and tinted or transparent enclosures.
KYDEX® T
KYDEX® T is a PMMA/PVC blend that’s manufactured by Sekisui SPI. This highly cosmetic material is available in a variety of colors and a wide range of sheet thicknesses. It’s also UL 94 V-0 flame retardant and combines good impact resistance with excellent chemical resistance.
KYDEX® T is hard and durable, but its stiffness may be a disadvantage for applications where greater flexibility is required. Applications for thermoforming material include machine housings, instrument
PP - Polypropylene
Polypropylene (PP) is like HDPE in that both materials provide excellent stiffness; however, PP isn’t as dense and can withstand higher temperatures. In addition, polypropylene is lightweight, has low moisture absorption, and provides impact resistance.
Among its disadvantages, polypropylene is difficult to process and has a high rate of shrinkage. It’s also difficult to paint, print on, or bond. At temperatures below freezing, this thermoplastic is prone to brittleness.
TPO - Thermoplastic Polyolefin
Thermoplastic polyolefin (TPO) has high impact strength even at low temperatures. It’s stiff, dimensionally stable, and chemically resistant. TPO is also lightweight, flexible, and suitable for outdoor use because it resists UV, ozone, and general weathering.
Although TPO is available in high gloss, it come in fewer colors than plastics like PVC. In addition, TPO can be difficult to process because it can sag when heated. TPO is not recommended for deep draws but has applications that include construction equipment enclosures.
PS - Polystyrene
Polystyrene (PS) is clear, inexpensive, recyclable, and offers excellent chemical and electrical resistance. This thermoplastic also has good electrical properties, good dimensional stability, and excellent resistance to gamma radiation. Heat distortion occurs around 200°C (392°F).
Despite these advantages, polystyrene cracks and breaks easily. It also provides poor UV resistance and may raise environmental concerns because it’s not readily recyclable. Applications for thermoformed PS include medical devices, auto parts, and home appliances.
PVC/ABS
PVC/ABS is a plastic blend that retains PVC’s inherent flame resistance. It’s also cosmetic, dimensionally stable, and easy to process. PVC/ABS impressions well with thermoforming tools and is ductile, meaning that it deforms significantly before breaking.
Although it contains PVC, this thermoforming material is not as stiff as pure polyvinyl chloride. It also has a lower heat distortion point than pure ABS. Applications for thermoformed PVC/ABS include fitness and medical equipment, fire-rated equipment enclosures, and mass transit interiors.
PVC/Acrylic
PVC/acrylic is easy to process and highly customizable. It also has excellent impact strength and chemical resistance. In addition, this thermoforming material resists staining. Heat distortion occurs around 71°C (160°F), which is significantly lower than materials like polystyrene.
PVC/acrylic lacks UV resistance and has a tensile strength that is lower than many other thermoforming materials. Applications range from aircraft interiors and electrical housings to business and medical equipment. Thermoformed PVC/acrylic is also used in mass transit.
PC - Polycarbonate
Polycarbonate (PC) is naturally transparent but can be tinted if necessary. This lightweight thermoplastic has high impact resistance and is a good electrical insulator. Compared to traditional glass, polycarbonate sheets are less likely to shatter. Lexan® is a well-known trade name.
Although it resists high heat, polycarbonate is not inherently flame-retardant; however, additives can be used to meet fire safety standards. Applications for thermoformed PC include signage and displays, medical devices, and lenses and covers.
PC/ABS
PC/ABS is less expensive than pure polycarbonate and has lower heat distortion. It’s also easier to process and provides greater chemical resistance. Among its advantages, PC/ABS has high strength, high stiffness, high heat resistance, and high impact resistance.
The disadvantages of PC/ABS include its low dielectric strength. Consequently, this thermoforming material may not provide sufficient insulation if high voltage resistance is required. In the automotive industry, applications include dashboards, door panels, consoles, and trim.
PEI - Polyetherimide
Polyetherimide (PEI) is an amber-colored, flame-resistant thermoplastic that withstands autoclaving. It has outstanding dimensional stability and maintains its excellent strength and rigidity even at elevated temperatures. Ultem® is a well-known trade name.
PEI is expensive, however, and it’s not available in a wide variety of colors. This thermoplastic can be attacked by strong bases and is prone to stress cracking in chlorinated solvents. Applications for thermoformed PEI include reusable medical devices and aerospace parts.
TPE - Thermoplastic Elastomer
Thermoplastic elastomer (TPE) has both thermoplastic and elastomeric properties. Many types of TPEs are available, including thermoplastic polyurethane (TPU); however, materials that combine polypropylene with rubber offer both fatigue resistance with flexibility.
TPEs tend to lose their rubbery properties if they are heated beyond 150°C (302°C). Elevated temperatures or pressures can also cause creep, a type of material deformation. Applications for thermoformed TPEs include car mats, which are produced with vacuum forming.
TPU - Thermoplastic Polyurethane
Thermoplastic polyurethane (TPU) combines elasticity and transparency with resistance to oil, grease, and abrasion. TPU also has excellent low-temperature flexibility and can be washed and sterilized. In addition, this type of thermoplastic elastomer has excellent tensile strength.
Some TPUs can absorb moisture, which may affect their mechanical strength and dimensional stability. TPUs also have a narrower hardness range than other thermoplastic elastomers. Medical products are a common application
In addition, UL 94 rated materials are available to meet all flammability classifications. Various highly engineered specialty resins or thermoplastic blends are available to meet specific industry standards such as aircraft interiors, mass transportation, FDA, etc.
Learn about the various properties of each of the plastics we use.
Knowledge and experience to make helpful recommendations
Decades of solving our customers’ material challenges means we have the material expertise to help you identify the most appropriate material for your application.
We also stay on top of the many new and innovative materials being developed for the thermoforming process, materials that can address the most demanding needs of our customers’ products.