Frequently Asked Questions

A thermoformed part is a plastic part produced using the thermoforming process. The low tooling costs and fast project lead times make thermoformed parts a very attractive manufacturing method.

formary offers production on roll forming and plate forming machines. Plate forming machines enable the production of large-volume thermoformed parts with thick walls. Roll forming machines are used more for large quantities with low unit costs due to fast cycle times.

Thermoforming is a process for forming thermoplastic materials. A thermoplastic is heated to a forming temperature at which the plastic assumes an elastoplastic state.

The heated material is then drawn into the desired shape on the mold. After cooling to solidification temperature, the shape of the mold is permanently imprinted on the thermoformed part, which is dimensionally stable. The part is then removed from the mold and post-treated by trimming the outer contour and finishing the surface.

• Vacuum thermoforming: Here, the plastic is pulled onto the mold by negative pressure. A vacuum pump sucks the air out between the material and the mold so that the plastic fits snugly. Vacuum forming is characterized by the following aspects:
  • Forming pressures up to approx. 1 bar
  • Ideal for simpler components
  • Less expensive tools and simpler machines
  • Particularly cost-effective for small or uncomplicated shapes
• Compressed air deep drawing: With this method, the heated material is pressed onto the tool using compressed air. Compressed air forming is characterized by the following aspects:
  • Pressures of up to 10 bar possible
  • Shorter heating and cooling times, resulting in faster cycle times
  • Suitable for more complex geometries
  • Saves time and reduces unit costs for higher quantities

Both processes are based on the same principle, but differ in terms of pressure level, complexity, and cost-effectiveness.

Alternatives in plastics processing include 3D printing and injection molding.
In simple terms, 3D printing techniques are used for smaller quantities, while injection molding remains an attractive option for large quantities.
Historically, thermoforming has therefore been positioned between 3D printing (small quantities or prototypes) and injection molding (large quantities). However, new and optimized techniques and materials are making thermoforming interesting in completely new areas that many companies are not familiar with.

Thermoplastics are plastics that are used in thermoforming. They can be shaped under heat and therefore have exactly the properties required for the thermoforming process.

Thermoplastics are divided into two main groups:

• Standard plastics: for applications with lower temperature requirements
• Engineering plastics: for areas where higher heat resistance or mechanical stability is required

There are also amorphous and semi-crystalline thermoplastics, which differ in their structure and therefore in their moldability.

The cost of a plastic thermoformed part can vary greatly—from a few cents to three-digit amounts per piece. The decisive factors are size, quantity, material, and post-processing.

• Tooling costs: must always be taken into account; for small quantities with a high proportion of the total costs
• Material costs: increase in significance with the number of units; for large series, they account for 70–80% of the total costs.
• Manufacturing costs: comparatively low thanks to efficient processes
• Energy costs: only account for a small proportion of the calculation
• Labor costs: mostly negligible due to high automation

The cost of a thermoforming tool can vary greatly:

• Simple tools: available from just a few hundred euros
• Special tools or punching tools: can reach mid-five-figure sums

Advantages over injection molding tools:

• Significantly cheaper
• Faster to manufacture

The tool set that must be created for each part is very important. It is ideal if the machine already has an existing substructure, i.e., only the forming tool and the cutting tool (punching tool or milling device) need to be created. Depending on the requirements of the deep-drawn part, additional tool components such as upper punches, ejectors, and automatic stacking stations can be created.

Deep-drawing tools are mainly milled and consist of two main components:

• molding tool
• cutting tool

When referring to the tool, this usually means the forming tool. However, a separating tool is also required for each thermoformed part.

Manufacture of the molding tool:

1. CAD/CAM data is created and serves as the basis for manufacturing.
2. A 3- or 5-axis milling machine machines a rectangular aluminum block until the desired tool shape is achieved.
3. This is followed by post-processing:
   • Insertion of vacuum holes
   • Deep hole drilling for cooling systems

Manufacture of the cutting tool:

• Depends on whether it is punched or milled
• Punching tools are divided into:
  • Knife cuts (steel strip cuts, formed with bending machines)
  • Shear cuts
• The cutting lines are inserted into prepared wooden blocks with laser-cut contours.

Depending on the part and the machine, the production of a thermoformed part can take from a few seconds to several minutes. Production is calculated in cycle times. A machine cycle is the complete process of running through the machine until the finished thermoformed part is available. If the punching is carried out directly in the machine, the cycle time ends immediately after the finished punched thermoformed part is removed from the machine.

If the trimming is carried out in a second step, either in a separate punching station or by milling, this time is added to the production time. It then depends on whether the thermoforming process itself or the post-processing step takes longer, which is where potential bottlenecks can arise. With multi-cavity tools, several thermoformed parts are produced in a single cycle, which minimizes the production time accordingly.

Almost all common thermoplastics can be used for thermoforming. The prerequisite is that the material is available in sheets or films, as pre-extruded material is used for thermoforming.

Important distinctions:

• Amorphous vs. semi-crystalline thermoplastics: Different molecular structures influence formability.
• Standard vs. engineering plastics: Mainly dependent on temperature resistance
• Mono-plastics vs. compounds/multi-layer films: Multi-layer films consist of different plastics that are extruded in layers.

Common plastics for thermoformed parts:

• Amorphous thermoplastics: ABS, PS, PMMA, PC
• Partially crystalline thermoplastics: PP, HD-PE, A-PET, PET-G, PVC

Amorphous thermoplastics soften at low temperatures and are easier to mold. Semi-crystalline thermoplastics remain solid for longer, as their crystalline structures only melt at high temperatures. The temperature window for molding is small, which makes processing more difficult.

Practical examples:

• HI polystyrene (HI PS, simply PS): Reference plastic for thermoforming, as it has very good thermoforming properties.
• Polypropylene (PP): More difficult to process due to high shrinkage (approx. 2%) and significant sagging, which complicate production. Additional machine components are sometimes required to stabilize the material.

Thermoforming machines heat the material, perform the forming process, cool it, and cut out the finished thermoformed part. The depth of the process, i.e., how many of the main steps in the thermoforming process are covered by the machine, depends on the selected process.

Machine types:

• Plastic sheet machine(Single-stage machines):
  • Usually only cover heating and molding
  • The separation is done separately.
• Rolling machines(Multi-station machines):
  • All steps—heating, forming, cooling, separating—are performed automatically in sequence.

Thermoforming machines are equipped with heating and cooling technology, as well as pneumatic, hydraulic, and electric drives, depending on the degree of sophistication of the machine, in order to execute the movement sequences required for production.

The semi-finished products used in thermoforming, in the form of films and sheets, are sourced from manufacturers of thermoplastic semi-finished products. These manufacturers extrude films and sheets from granulate of the corresponding plastic types in the desired cut shape, thickness, and color. They can also extrude various additives and color strips into the semi-finished product and fulfill other special requests.

It is always very important that semi-finished products are often extruded to order. Since the extruders have to be laboriously set up before production, there are always minimum order quantities for the purchase of semi-finished products. Here, a distinction must be made between rolls and sheets:

• Rolls: typically at least 500 kg for common thermoplastics
• Sheet cut-to-size: often available in smaller quantities directly from plastics dealers

Thermoforming offers numerous advantages in the manufacture of plastic products:

• Low tooling costs compared to injection molding
• Short lead times for prototypes and series production
• Wide range of materials for different requirements
• High reproducibility and consistent quality
• High-quality appearance of the finished parts
• Flexibility in design and shaping

Thermoforming is particularly economical for quantities ranging from a few hundred to approximately 10,000 parts.

Plastic thermoforming is used in many areas. At formary, we divide the areas of application into five categories:

1. Transportation and storage of goods:
   • Trays and workpiece carriers for industrial storage and transport
   • Tailor-made for customer products and components
   • Often used in KLTs or cardboard boxes, stacked for space-saving storage
2. Automation:
   • Trays for automated loading and unloading by robotic systems
   • Advanced features such as coding, alignment, and positioning
   • Intensive development process for optimization for machine operation
3. Inlays:
   • Custom-fit inserts for drawers, toolboxes, or folding boxes
   • Protect and secure products inside containers
4. Containers:
   • Tanks and containers for industrial and medical applications
   • Various shapes and sizes depending on the area of application
5. Covers / technical deep-drawn parts:
   • Housing for protection and aesthetic enhancement
   • Use in medical technology, automotive industry, and other technical fields

Yes, thermoformed plastic parts can be completely recycled and reused as recyclate. There are two different recycling cycles.

1. Post-Industrial Recycling:
   • Used directly in production
   • Punching and milling residues are collected and returned to the material cycle.
   • New granulate is produced from the leftovers, which is then used to make new films and sheets.
2. Post-Consumer Recycling:
   • The end user is responsible
   • Companies: Thermoformed parts can be completely recycled at the end of their life cycle, e.g., through take-back programs such as those offered by formary.
   • Private individuals: Disposal via the yellow bin, so that the material is forwarded to the nearest recycling company.

A prerequisite for successful forming is that certain geometric requirements must be met, since, unlike injection molding, the tool only has contact with the material on one side. These limitations can be circumvented by Design for Manufacturing (DfM) if taken into account early on in the development process.

formary is a platform for all types of deep-drawn parts. From the initial enquiry to the order and delivery, you receive data, samples and series parts in a personalised, streamlined and digital process. You can enter your enquiry in our configurator, which guides you through the process and ensures that you don't forget any information that could lead to time-consuming queries later on. Once you have submitted your request, you will receive your quote within 24 hours. Leave everything to us: we automatically calculate your price, select the right supplier, choose the appropriate sample and series production, and coordinate all processes. We are your sole contractual partner.

Your thermoformed part is manufactured by one of our processors from our production network in the DACH region. All our suppliers are ISO 9001 certified and manufacture to the highest quality standards. Once your request has been checked and automatically calculated and all production-related parameters have been clarified, you will receive your quote. 
Once you have placed your order, the appropriate supplier will receive the production order.
After assignment, we will keep you regularly updated on the progress of your production and will be available to answer any questions you may have at any time via all formary channels, such as chat, email, telephone, and video call.
We take care of the technical clarifications, monitor timely completion, and check your parts after completion by our internal QA department.
Once approved, we take care of the logistics to ensure that your parts arrive on time. You can also handle invoicing and any potential complaints through us.

The use of formary is free of charge. You can place as many inquiries with us as you like and contact us proactively at any time for development projects. You will not incur any costs until you place an order for your deep-drawn parts.

Payment is made upon receipt of the invoice after successful delivery of your deep-drawn parts. Once we have dispatched your order, you will receive your invoice digitally or by post, as requested. In individual cases, we reserve the right to request payment in advance.

After submitting your request, you will receive a summary of the request parameters by email. You can double-check these, save them as a PDF, or print them out if necessary. We will then automatically calculate the unit costs for your deep-drawn part and the tool. You will receive the quote by email within 24 hours. You can also save this as a PDF or print it out. If you have any questions in the meantime or after receiving the quote, you can contact us at any time via your preferred channel.

formary calculates your unit prices and the tool based on the parameters of your request and other parameters we have defined after reviewing your requirements for the deep-drawn parts. The price is determined by calculation data from our database, experience, and current market data. We use this information to select the machine, design the mold surface, and determine the tool design. 
You will receive the quote within 24 hours, which will be manually checked for plausibility by a formary project manager before dispatch.

It's up to you. formary offers two options.
1) We can check the thermoformed part you have created in the CAD program for feasibility and calculate a quote for you, or 2) we create your concept and thermoformable data based on the information you provide in the configurator. We will then send these to you for review and approval. If you notice any further issues when reviewing the data, we will incorporate these. Once approved, the thermoformed part will go into sampling.

You can upload your own data to us.

When calculating a product in the areas of goods transport and storage, automation, and inlays, CAD data for your components is required at the latest when formary creates the data for the thermoformed part. You can upload this directly to the configurator with your request or send it to us later.

You can also load thermoformed parts for which data already exists or which you have created yourself into our configurator and obtain a quick quote.

We would be happy to sign a GHV in advance – send us your document to info@formary.de and we will return it to you as soon as possible after review.

We require CAD data for your components and requested deep-drawn parts. We can work with step, IGS, DXF, and Parasolid.

There is no flat-rate minimum order quantity: formary processes every request. The minimum quantity depends on the material and the specifications of the deep-drawn part. For small quantities of standard materials, we can draw on our suppliers' stock and thus also produce very small quantities. For special colors, thicknesses, cut sizes, or compounds, we will check the material availability options after receiving your request.
 

Depending on availability, we can produce small quantities starting at 30 parts or even carry out pure prototype orders.

No, we do not have a minimum order value.

You can cancel your orders after placing them. This option depends on whether the material has already been manufactured and/or delivered for your order. If you wish to cancel, please contact us directly by phone and we will check all options immediately.

We match the assignment internally. Immediately after you place your order, the most suitable partner is selected automatically based on production capabilities, machine equipment, material stock and availability, as well as free production capacity. We clarify all aspects relevant to production in consultation with our partner. Since we take our partners' capacities into account, you can be sure that your delivery times will be met reliably.

formary is also your sole point of contact for complaints. 
Once you have determined the reason for the complaint, please report the quantity involved to us immediately. Let us know how you would like us to proceed (replacement, credit note) and we will take care of everything else. We will remain in constant contact with you throughout the process. As our partners have highly trained staff, work in accordance with ISO 9001 and we carry out internal quality assurance checks on every delivery, this situation is very rare.

There are hundreds of thermoformers in the DACH region alone. Therefore, it is always possible that you may receive a cheaper offer. However, it is important to keep an eye on the total costs: Procurement involves immense costs that are not reflected in the thermoformed part itself. Often, a lot of time and coordination goes into finding the right supplier. Given the number of product groups and manufacturing processes that a purchaser has to keep track of these days, there is often a lack of in-depth understanding of the complex interrelationships within supply chains. formary resolves these issues through proactive support and product development. Long waiting times for quotes, poor supplier availability, no proactive input on price options and delivery possibilities – all this is eliminated through cooperation with formary.
Our lean and automated processes save you a lot of time and money at potential interfaces. This helps you keep an eye on the overall price. Just give us a try and see for yourself. :-)

Since our production network always has free capacity, short delivery times are guaranteed.

Depending on your quantity and how exotic your desired material is, you can expect the following delivery times:

• Data creation in 1-3 business days
• Samples in 2-4 weeks
• First series parts 2-4 weeks after approval

If you are in a hurry, you can contact us directly by phone at any time.

Freight costs are based on the number of Euro pallets and the total weight. The distance from the manufacturing partner company is another factor.

Since we carry out quality checks and approvals before delivery, and the shipping process is then triggered automatically, you cannot pick up your delivery.

You can obtain initial sample inspection reports (EMPB) from formary. We can also provide you with additional documents such as material data sheets, ROHS, and Reach for your order at any time.

After reviewing and automatically calculating your request and clarifying all parameters relevant to production, you will receive your quote.
Once you have placed your order, the appropriate supplier will receive the production order.
After assignment, we will keep you regularly updated on the progress of your production and will be available at any time to answer your questions via all formary channels, such as chat, email, phone, and video call.
We take care of the technical clarifications, track timely completion, and check your parts after completion by our internal QA. After approval, we take care of the logistics so that your parts arrive on time. You can also handle invoicing and potential complaints through us.

Deep-drawn parts are manufactured by a selected partner company that has the appropriate equipment, machinery, and free production capacity to produce your order optimally.

You will receive your order confirmation 2-3 working days after placing your order, provided that all important delivery dates for materials, tools, sample production, and series production have been entered into the production schedule. We will keep you informed in the meantime. As a general rule, you can refer to our standard delivery schedules and our offer.

Unfortunately not, we specialize in supplying businesses.