Thermoforming Dimensions and Tolerances

Our thermoformed plastic parts are made to meet the following dimensional and tolerance requirements for all of your part needs:

  • ​Formed Dimensions reference trimmed dimensions for a heavy-gauge thermoformed plastic part whether it has been produced by vacuum pressure forming or twin sheet process.
  • Trimmed Dimensions apply to our CNC or hand trimming processes
  • Secondary Operation dimensions apply to all of our finishing processes.
  • Fabricated Part Tolerancing are our maximum limits for dimensional variation that we look for in our Quality Assurance Process for your thermoformed part.

Formed Dimensions:

Certain materials and geometries may require higher tolerances.
Any trim to non-tool surface is “Reference Only”.

US Units Metric
Machined Aluminum Tool
First 12″
± .001″ each additional inch
± .020″ First 300mm
± .025mm each additional 25mm
± .50mm
Hole diameters (formed) ± .010″ Hole diameters (formed) ± .25mm
Angles ± 1° Angles ± 1°
Cast Aluminum Tool
First 12″
± .001″ each additional inch
± .030″ First 300mm
± .025mm each additional 25mm
± .75mm
Hole diameters (formed) ± .010″ Hole diameters (formed) ± .025mm
Angles ± 1° Angles ± 1°
Prototype Aluminum Tool  (no temperature control)
First 12″
± .001″ each additional inch
± .045″ First 300mm
± .025mm each additional 25mm
± 1.20mm
Hole diameters (formed) ± .015″ Hole diameters (formed) ± .40mm
Angles ± 2° Angles ± 2°

 

Trimmed Dimensions:

Primary:

US Units Millimeters
1 Decimal place
2 Decimal places
3 Decimal places
± .050″ per first 12″
± .030″ per first 12″
± .020″ per first 12″
1 Decimal place
2 Decimal places
3 Decimal places
± 1.25mm per first 300mm
± .75mm per first 300mm
± .50mm per first 300mm
± .001″ each additional inch up to 48 inches
± .002″ each additional inch over 48 inches
± .025mm each additional 25mm up to 1200mm
± .050mm each additional 25mm over 1200mm
Hole-to-Hole ± .015”, first 6″ Hole-to-Hole ± .40mm first 150mm
± .001″ each additional inch up to 48″
± .002” each additional inch over 48″
± .025mm each additional 25mm up to 1250mm
± .05mm each additional 25mm up to 1250mm
Hole diameter ± .010″ up to .500″ Hole diameter ± .25mm up to 12.5mm
± .001″ each additional .100″ ± .025mm each additional 2.5mm

 

Secondary Operations:

Silk screening, labels block gluing, etc.

US Units Metric
± .100″ for first 12″ from a trimmed or measurable tool surface
± .002″ each additional inch

± 2.5mm for first 300mm from a trimmed or measurable tool surface
± .05mm each additional 25mm

Note: These are Profile’s recommended standard tolerances for our thermoforming (vacuum, pressure and twin sheet) and CNC trimming operations. If there are specific features or dimensions that must be held to a tighter range then we can discuss possible alternatives to accomplish your specific needs.

 

Fabricated Part Tolerancing:

Dimension US Units Dimension Metric
0 – 5.0″ ± .010″ 0 – 150mm ± 0.25mm
5.0” – 15.0″ ± .020″ 151 – 400mm ± 0.5mm
15.0” – 30.0″ ± .040″ 401 – 750mm ± 1.00mm
30.0” – 60.0″ ± .060″ 751 – 1500mm ± 1.50mm
Over 60.0″ add .001″ per inch Over 1500mm add .025mm per 25mm
Angles ± 1° Angles ± 1°

Note: Sheet thickness is usually ± 10%, however starting thickness may vary depending on specific material selected.

 

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