Thermoforming Materials Selector
Use the table below to evaluate thermoforming materials based on the following properties:
| Material | Selector |
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This information is also available as a PDF download and as a CSV file.
Full Name
Mechanical
Electrical
Thermal
Chemical Resistance
ChemicalNon-Resistance
Weathering
Flammability
ABS
Acrylonitirle-Butadiene-Styrene
Hard, stiff, very good impact strength, scratch-resistant, good appearance (smooth and textured)
Good electrical insulating properties, low electrostatic discharge (semi-conductive grades available)
Working temperature from -40°C to +90°C. Higher heat grades available up to 105°C. Thermoforming range 150°C to 200°C. Pre-drying recommended. Mold shrinkage 0.5 to 0.7%.
Water, brine, dilute acids and bases, saturated hydrocarbons, animal and vegetable fats and oils. Food-approved grades available.
Aromatic hydrocarbons, chlorinated hydrocarbons, concentrated acids and strong oxidizing agents
Continuous outdoor exposure causes deterioration of the impact strength. Lighter colors are prone to yellowing. Some UV resistance obtained by the use of dark carbon-based colors.
Burns if exposed to flame or sufficient heat source. Continues to burn when flame removed, emitting dense smoke. Self-ignition temperature approximately 450°C. Extensive range of flame-resistant grades, all self-extinguishing.
ASA
Acrylonitirle-Styrene-Acrylic Ester
Hard, stiff, high impact strength, good scratch resistance
Insulating properties, low electrostatic discharge
Working temperature from -40°C to +90°C. Thermoforming range 150°C to 200°C. Mold shrinkage 0.5 to 0.7%.
Similar to ABS. Slightly better resistance to environmental stress cracking.
Similar to ABS
Excellent resistance to aging and weathering
Similar to ABS. Self-ignition approximately 400°C.
HIPS
Polystyrene High Impact
Hard, stiff, good impact characteristics in impact-modified versions (low extendibility, notch sensitive)
Good electrical insulation properties. Low dielectric loss factors. Develops electrostatic charge. Semi-conductive grades available.
Working temperature up to approximately 70°C. Thermoforming range 140°C to 180°C. Mold shrinkage 0.5 to 0.7%.
Alkalines, bases, alcohol, dilute acid, water, brine
Aromatic and chlorinated hydrocarbons, ether, ketones, strong oxidants, solvents
Unfit for outdoor usage. Weatherable grade available.
Similar to ABS. Flame-retardant grade available.
PC
Polycarbonate
Very high impact strength, rigidity, toughness, prone to notch sensitivity
Good electrical insulating properties
Excellent temperature resistance. Heat distortion temp 125°C. Thermoforming range 190°C to 210°C. Pre-drying required. Mold shrinkage 0.5 to 0.7%
Dilute acid, water, brine
Prone to stress cracking on exposure to a number of relatively common solvents. Care should be taken in specifying cleaning agents.
Good weathering characteristics. Surface can be affected by environmental pollution.
Unmodified material will ignite when exposed to flame or sufficient heat source. A range of flame-resistant grades is available.
PE
Polyethylene High Density (HD) and Low Density (LD)
High impact strength. Surface hardness and stiffness increase with the density of the material. PE-LD is soft and pliable. PE-HD is relatively hard and stiff.
Very good electrical insulating properties. Develops electrostatic charge. Semi-conductive grades available.
Excellent low temperature resistance: -50°C max. Continuous working temperature is dependent on density of material, up to 80°C. Thermoforming range 50°C to 180°C. Mold shrinkage 1.5 to 2.5%.
Highly-resistant to many chemicals, oils and petrol
Strong oxidizing agents. Concentrated acids.
Moderately resistant, particularly in dark carbon-based colors
Burns readily. Continues to burn after removal of flame. Self ignition at 360°C.
PP
Polypropylene Co-Polymer (C) and Homo-Polymer (H)
High impact strength and rigidity. Prone to brittleness at temperatures below freezing.
Very good electrical insulating properties. Inclined to electrostatic charge. Anti-static and semi-conductive grades available.
Max. continuous working temperature from 100°C to 110°C. Thermoforming range 50°C to 180°C. Mold shrinkage 1.5 to 2.5%.
Excellent resistance to most chemicals at room temperature
Strong oxidizing agents, and hydrocarbons at elevated temperatures
Similar to polyethylene
Similar to polyethylene
PMMA
Acrylic
Hard and stiff with good dimensional stability. Often co-extruded within an ABS substrate to reduce tendency to brittleness.
Good electrical insulating properties. High dielectric strength. High electrostatic charge.
Working temperature up to 80°C. Retains strength until close to softening point.
Aliphatic hydrocarbons, fats, oils, diluted acids and bases up to 60°C
Chlorinated hydrocarbons, ketones, alcohols
Excellent resistance to aging and weathering
Burns readily, giving off a characteristic fruity odor
PVC
Polyvinyl Chloride
Appears as a white, brittle solid. The density is around 1.3–1.45 g/cm³ for rigid PVC.
PVC is a good insulation material. Thanks to its good dielectric strength.
Its melting point ranges from 100–260°C. Decomposition of PVC starts at 250°C; first, dechlorination and dehydrogenation take place; later, at around 450°C, the breaking of the C─C bond occurs.
It is odorless, insoluble in water and alcohol. PVC has stable chemical properties. It is insoluble in water, alcohol, and gasoline, and has low gas and water vapor permeability.
Slightly soluble in tetrahydrofuran (THF). The most common PVC solvent products are made from propylene glycol (PG) but there are also other variations that use other solvents such as acetone and butyl acetate.
PVC is often used for window frames, doors, guttering and cladding, as it is robust, weather-resistant and easy to clean.
PVC is resistent to ignition. The temperature required to ignite rigid PVC is more than 150 degrees celsius higher then that required to ignite wood. The ignition of common flexible PVC is lower, but with specialised formaulations, it may be significantly increased.
PETG
Polyethylene Terephthalate Glycol
High strength-to-weight ratio and is shatterproof. It’s also lightweight and has low gas permeability.
Electrically insulating.
The main disadvantage of PETG is that it has a lower heat resistance than other polymers. Although it’s free from BPA and phthalates, PETG can degrade the taste of food and beverages that are stored for extended periods of time.
Because it won’t react with water, PETG is sometimes used in food-contact applications.
Not compatible with acetone and strong organic solvents
PETG exhibits varying weathering properties influenced by factors like UV exposure, temperature, and moisture. While generally resistant to many chemicals and exhibiting good weatherability, PETG can degrade over time through processes like photodegradation, hydrolysis, and thermal degradation, leading to changes in its physical and chemical properties.
PETG is a thermoplastic polymer, and like many plastics, it can be ignited and burned under certain conditions
PVC/ABS (amorphous)
Polyvinyl Chloride / Acrylonitrile-Butadiene-Styrene Common Brand Names: Royalite® R57 or R59, KYDEX® 430
It is an extremely user friendly material. The hot strength and formability of this material are excellent. Secondly, this material is very cosmetic and because of its flow characteristics, it really lends itself well to the pressure forming process. A third plus is the dimensional stability of the material after it is formed.
Not electrically insulating
Because it is an alloy, it is not as stiff as straight PVC. It also does not have a heat distortion point as high as ABS, but it is higher than PVC.
PVC/ABS offers chemical resistance.
Not compatible with esters, ketones, nitric acid, and some chlorinated hydrocarbons
For applications requiring exposure to outdoor elements, it's crucial to specify a weatherable grade of Royalite. These grades typically incorporate UV stabilizers or a UV-resistant cap layer (like acrylic) to improve performance and prevent degradation.
It is fire-rated and passes the Federal Aviation Administration (FAA) requirements for flammability, specifically FAR 25.853 (a)(ii) and FAR 25.853b at thicknesses of 0.047 inches and above.
PMMA/PVC (amorphous)
[PVC/ACRYLIC] Common Brand Names: KYDEX® T, Royalite® R52
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.
PMMA/PVC is known for its good electrical insulation properties. It has a high dielectric strength, meaning it can withstand high voltages without allowing electrical current to pass through.
PMMA/PVC is typically formed between 325°F and 390°F (163°C to 200°C). It's crucial to heat the material evenly and avoid exceeding 400°F (204°C).
PMMA/PVC chemical resistance is another important factor for electrical applications, as it can withstand exposure to various chemicals and cleaning solutions.
Not compatible with aggressive solvents like acetone, MEK, Xylene, Toluene
PMMA/PVC offers various weathering properties that make it a suitable material for outdoor use, especially certain grades designed for such applications.
PMMA/PVC is known for its flame retardancy, often meeting UL94 V-0 and 5V ratings. This means it self-extinguishes quickly when exposed to a flame, making it a safer choice for electrical applications.
The core of this text is based on information from Spartech, LCC. Various factors influence the processing and use of any thermoplastic. The information presented here does not relieve readers of the need to carry out their own experiments.
This information does not constitute a legally binding assurance of particular properties or suitability for a particular end use. Existing patent rights must be observed. Please consult Profile Plastics for further information about thermoforming material selection. Brand names shown here are the properties of their respective owners.