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Plastic Injection Molding vs. Thermoforming

  • November 5, 2022
  • General
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Plastic fabrication is a popular way to manufacture products. It’s favored by many due to its affordable cost, easy malleability and modifications, and durability. Injection molding is a popular method for those looking to mass produce parts with intricate shapes.

Plastic Injection Molding

The plastic injection molding process involves injecting molten plastic material into or around a mold. The material hardens as it cools until it reaches a state where it is fully formed and safe to remove from the mold.

There are many benefits to plastic injection molding. It allows for the efficient manufacture of large volumes of uniform parts and products, keeps costs low, and plastics are available in a multitude of colors to suit any product.

Injection molding also allows for a number of different materials to be injected. Both thermoplastics, such as ABS, ETPU, Nylon or Polycarbonate, as well as Thermosets (silicone or fluorosilicone) can be used for injection molding. Depending on what is required, the products can vary from extremely durable to soft and malleable.

As versatile as it is, injection molding also has its drawbacks. Some common defects include blisters, a raised area on the surface due to too much heat or cooling too quickly. Other defects include burn marks, burrs (extra material attached to the finished piece), embedded contaminates, flow marks, or sink marks, small holes along the surface of the piece.

Thermoforming

A great alternative to plastic injection molding is thermoforming. This process uses thin or thick gauge plastic sheets that are heated until they’re pliable and then formed over or inside of a mold using either vacuum suction or pressure. Both are effective ways to remove air bubbles and stretch the plastic around the mold.

Vacuum forming is better suited for shallow plastic parts that need to be formed into cavities. Fewer materials are best suited for vacuum forming but components made from this process can replace complex fabricated sheet metals fiberglass, or plastic injection molding.

There are various types of thermoforming processes depending on the type and number of plastic sheets used. All of them share the same advantages including:

  • The superior surface quality of the finished part
  • Easily used to manufacture large parts
  • Fast turnaround
  • Low cost for tooling
  • Wide selection of materials
  • Inexpensive and fast adjustments to the design

Some advantages to thermoforming include the ability to produce several finished products from the same material. It also has been shown to be the quickest and most affordable means of producing parts. Thermoforming is also ideal for producing large parts. It is easy to add details and offers more freedom in design.

This technique is widely used in industries such as medicine, aviation, and public transport. Clamshell packaging, packaging blisters, shipping trays, packing inserts, pop displays, material and handling trays and covers are just a few of the common items you may see that are products of thermoforming.   

Materials

The number of different materials that can be used with thermoforming also increases its versatility. Here are just a few of the materials that are highly suitable for thermoforming.

  • ABS (Acrylonitrile Butadiene Styrene)
  • Acrylic (Polymethyl Methacrylate, Plexiglass or PMMA)
  • HMPWE (High Molecular Weight Polyethylene)
  • KYDEX (PMMA/PVC blend)
  • PC (Polycarbonate)
  • Pennite (glass-filled nylon)
  • PEI (Polyetherimide Ultem)
  • PET (Polyethylene Terephthalate)
  • PP (Polypropylene)
  • Royalite
  • RPET (Reprocessed Polyethylene Terephthalate)
  • TPO (Thermoplastic PolyOlefin)
  • Vinyl

Thermoplastic materials exhibit the same characteristics as rubber and can have the same strength as aluminum. Different materials can retain their properties from 100 degrees F to 600 degrees F. If metal of carbon is added, they can be electrically conductive.

Both plastic injection molding and thermoforming are great types of manufacturing and are both customizable and affordable. Your requirements and vision for your project or parts determine which method is the best for your needs.

Grand Canyon Plastics

Grand Canyon Plastics is the leading provider of thermoformed plastics in Phoenix, Arizona, and the surrounding areas. We can take your idea and turn it into a reality by completing every step of the process under one roof to deliver high-quality products at competitive pricing.

Contact us today to discuss your project needs or schedule a free consultation.

 

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