As discussed in ScienceDirect’s article “Thermoforming Process,” thermoforming is a key process in polymer packaging, especially for shaping thermoplastic film and sheet. Although historically underutilized, thermoforming has gained popularity due to its economic benefits and adaptability in producing diverse plastic products, from food packaging and disposable plates to blister packs and interior paneling.
Thermoforming begins by heating a plastic sheet until it becomes flexible enough to mold. This heated sheet is then pressed over a mold, where minimal force is applied to shape the material. Once cooled, the product hardens, preserving the mold’s form, after which it’s cut to the desired size. A specific variation, vacuum forming, applies heat to the sheet and creates a vacuum beneath it, forcing the plastic to adhere tightly to the mold’s contours.
The complexity of the thermoforming process, with its numerous variables, has spurred interest in computer simulations to optimize production. Factors such as plug material, design, and temperature directly affect the final product’s wall thickness. For example, flat-bottom plugs help retain thickness at the product’s base, while rounded plugs allow the sheet material to slip and redistribute toward the side walls, enhancing flexibility in design.
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Article with all rights reserved, courtesy of sciencedirect.com
