Ideal for Great-Perfoming Hollow and Lightweight Plastic Parts
- Uniform wall thicknesses
- Lightweight yet strong
- Ability to combine material types, thicknesses and/or colors on each side
- Lower tooling costs than blow molding
- Faster turnaround and lower part cost than rotational molding
Twin-Sheet Forming Works Best If You Need…
Recognize your needs in any of the following? Twin-sheet forming could be your solution:
Highly detailed cosmetic parts
Thanks to the advantages of pressure-forming used in the twin-sheet process, highly detailed—and lightweight—cosmetic parts are possible.
Lower cost tooling
Quick turnaround for parts at a lower cost
We can produce plastic parts at a lower cost and a faster rate using a twin-sheet thermoforming process versus rotational molding—and at higher volumes.
Difficult draw ratios
Flexibility with seam lines
Durability and industry-compliance
Volumes in the hundreds to thousands
Lightweight yet strong
Understanding the Twin-sheet Forming Process
Twin-sheet forming is the simultaneous heating of two thermoplastic sheets and forming them between two pressure-forming tools.
First, a vacuum force is applied independently to pre-form each sheet. Once formed, the tools are quickly brought together, and compressed air is injected into the space to force the material to fuse together.
The result is a hollow plastic part that resembles rotationally molded or blow molded parts. But twin-sheet parts provide the added advantages inherent to thermoforming, like faster turnaround for strong, lightweight parts with high performance demands. See more details below.
Twin-sheet vs. blow molded and rotationally molded parts
So why twin-sheet forming? Consider this: Rotationally molded parts tend to be heavier, with thick corners but with thin walls. Twin-sheet parts, on the other hand, have more uniform wall thicknesses, and will be lighter.
And compared to blow-molded parts, twin-sheet forming allows for the use of a plug and/or the insertion of molded-in components into the hollow areas of the part—virtually impossible for blow-molded parts.
How Customers Benefit from Our Extensive Twin-Sheet Forming Experience
- Door panels/trays
- Air ducts
- Insulated cap or top
- Engineered shock absorbers