Thermoforming
Custom Thermoforming
STM Plastics is a custom thermoforming manufacturer that makes it easy for you to make a new part, switch suppliers, or on-shore your production. Based in Augusta, Kansas, we ship custom parts nationwide and even internationally. We run a wide range of materials and gauges, form parts up to 10 feet, and finish them in-house with trimming, deburring, and assembly, including CNC trimming capabilities. We’ll tell you honestly whether thermoforming (also known as vacuum forming) is the right process for your part, and if it is, you’ll work with people who answer the phone and keep your project moving.
What We Can Form
Part size up to 10 feet – We can form finished parts up to roughly 10 feet. Thermoforming is great for large parts and can make more economic sense relative to other plastic manufacturing processes.
Thin and heavy gauge – We form material from .020″ up through .400″ and beyond. If you have a heavier requirement, ask us. We’ll work with you to find a solution.
Materials we run – HMWPE, HDPE, ABS, HIPS, and PETG are our most common. We also run Polypropylene, PVC and Kydex (a PVC/acrylic alloy). If your application calls for a material you don’t see here, again, ask us. We may be able to run it, or find an alternative. Learn more about thermoforming materials here.
In-house finishing – Forming is only part of the job. We trim and deburr every part, run CNC operations, and handle assembly if needed so your part leaves finished.
See examples of our work from replacement trash can lids to mausoleum trays, to just a few of our custom projects.
Is Thermoforming Right for Your Part?
There are pros and cons to every plastic manufacturing process, so it’s important to find the right process for your application. A few reasons you might want to consider thermoforming for your project are:
- Tooling Costs – Upfront tooling costs for thermoforming are less expensive and have shorter lead times than for other types of plastic manufacturing.
- Low to Medium Volume Production – The low initial investment makes thermoforming a great option for low to medium volume production run.
- Time to First Production – The shorter lead times for thermoforming tooling can help you get your first part or product faster.
- Large Parts – Relative to other types of plastics manufacturing, thermoforming can produce large parts easily and economically. At STM, we can run parts up to 10 feet in length. Check out our post on large part thermoforming.
- Prototyping – There is still upfront tooling costs associated with prototyping via thermoforming, but an economical low-volume tool can be made and used for prototyping parts before investing in a full-production tool. With the rise of additive manufacturing, size, material and application should all be considered to determine the best method for prototyping your part.
The size, geometry, and volume of your part drive the decision more than your industry. We form parts for machine shops, packaging operations, battery manufacturers, industrial and construction equipment manufacturers, waste management, pet care, lawn and garden, and many more industries, but what matters is the part, not the sector.
If you’re working on a design or wondering if your part can be thermoformed, our thermoforming design guide will help. It covers draft angles, draw ratios, corner radii, and material selection. Or, call us and we’ll work with you to figure out if it’s a fit.
How to Work With Us
All projects start with a conversation. Call us, fill out our RFQ form, or send us a description of your part with rough dimensions, the material if you know it, and an estimate of how many you need and how often. We’ll follow up, and if it makes sense, we’ll ask you to send a drawing so we can quote it accurately.
What is Thermoforming?
Plastic thermoforming (also known as vacuum forming) is a manufacturing process used to create plastic parts and products. The process involves heating a plastic sheet until it becomes pliable, and then forming it into a desired shape using a mold, or tool. It is a versatile and cost-effective process that can be used to create a wide range of products, from simple trays and packaging to complex automotive parts and medical devices.
The video below shows one of our pre-formed ponds being formed. It has a deep draw, so we’re using an assist plug to help push the material into the tool. This helps maintain wall thickness in the deeper portion of the tool.
Basic steps of the plastic thermoforming process:
Material selection
The first step is to choose the appropriate plastic material for the intended application. The material needs to be able to withstand the thermoforming process and provide the desired properties, such as strength, flexibility, or clarity. The material will be sourced in the form of plastic sheet. Check out our thermoforming design guide for more information on some common thermoplastic materials. We are more than happy to help you choose your material or suggest substitute materials if needed.
Heat
The plastic sheet is then heated until it reaches a pliable state. This can be done using an oven or a specialized heating system.
Form
Once the plastic sheet is heated, it is placed over a mold or tool, which is designed to create the desired shape of the final product. The plastic sheet is then pulled down onto the mold using a vacuum, which forces the plastic to form to the mold’s shape.
Cool
After the plastic has been formed, it is cooled to set the shape and lock in the desired properties.
Trim
Finally, the excess plastic around the edges of the part is trimmed off, and any finishing touches are added.
