Frequently Asked Questions

A thermoformed part is a plastic part produced using thermoforming. Advances in machine technology and innovative materials are making thermoformed parts increasingly attractive for a wide range of applications. Low tooling costs and fast project lead times make thermoforming a very attractive manufacturing method.

formary offers production on roll forming and plate forming machines.

Processors usually specialize in one of the two processes. Plate automatic machines allow the production of large-volume deep-drawn parts with thick wall thicknesses. Roll automatic machines are more commonly used for large quantities with low unit costs due to fast cycle times.

With formary, you have access to both processes, as well as different machine sizes, manufacturers, and types that are suitable for various applications.

Thermoforming is a process for forming thermoplastic materials. A thermoplastic is heated to a forming temperature at which the plastic becomes elastoplastic. 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 transferred to the deep-drawn part, which is now dimensionally stable. The part is then removed from the mold (demolded) and post-processed by trimming the outer contour and finishing the surface.

Two techniques are available for pressing the heated plastic onto the mold, which will give the deep-drawn part its shape: vacuum deep drawing and compressed air deep drawing.

In vacuum deep drawing, a vacuum pump creates a vacuum that sucks the material onto the tool. Due to lower forming pressures of max. 1 bar, this process is primarily used for the production of simpler deep-drawn parts that need to be manufactured cost-effectively, as cheaper tools and simpler machines are usually used.

In compressed air deep drawing, the material is pressed onto the tool using compressed air. Significantly higher pressures of 10 bar are possible here. Due to the shorter heating and cooling times required (due to higher pressures), faster cycle times can be achieved, which is beneficial for the unit price. More complex geometries can also be formed using this method.

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. A thermoplastic can be shaped under the influence of heat and therefore has the necessary properties for the deep-drawing process. Thermoplastics are divided into standard plastics and engineering plastics, with heat resistance being the primary factor in this classification. There are also amorphous and semi-crystalline thermoplastics, which differ in their structure and therefore in their formability.

A thermoformed part can cost anywhere from a few cents to hundreds of dollars per unit, depending on size, quantity, material, and post-processing.
The most important cost factors are the tooling, which is always required, material, manufacturing, energy, and labor costs.
Labor costs are relatively negligible due to high levels of automation.
Energy and manufacturing costs also account for a relatively small proportion of the calculation.
The two relevant cost factors are the tooling and the material used. The proportions shift as the number of units increases, as the tooling initially accounts for a large proportion of the total costs, but is then quickly overtaken by the material costs. For high volumes, material costs account for between 70 and 80% of the unit costs. See the Design Guide for more information.

A deep-drawing tool can be purchased for a few hundred dollars, but the price can rise to mid-five figures for special components and punching tools. In general, deep-drawing tools are many times cheaper than injection molding tools (and can also be produced much faster).
The tool set that has to be created for each part is very important. It is best if the machine already has an existing base, meaning that only the molding 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 milled, i.e. manufactured using a cutting process. Deep-drawing tools are divided into forming tools and cutting tools.

When referring to the tool, the forming tool is usually meant – however, a cutting tool is also required for each deep-drawn part.

CAD/CAM data is created for the forming tool. The milling program of the 3- or 5-axis milling machine then carries out the milling work. A rectangular aluminum block in the appropriate size category for the tool is placed in the tool mold. Once the shape of the tool has been milled, further finishing steps are carried out, such as drilling vacuum holes and deep holes for cooling systems.

The cutting tool depends on whether punching or milling is used. Punching tools are divided into knife cuts and shear cuts. Knife cut tools are in the form of strip steel cuts. The cutting lines are produced with bending machines and inserted into a wooden block with laser-cut contours.

The manufacturing cycle of a thermoformed part can range from 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 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 deep drawing process itself or the post-processing step takes longer, where potential bottlenecks can arise. With multi-purpose tools, several deep-drawn parts are produced in a single cycle, which minimizes the production time accordingly.

Virtually all common thermoplastics can be used for deep drawing. It is important that the material can be extruded in the form of sheets or films, as pre-extruded material is used in deep drawing. A distinction is made between amorphous and semi-crystalline thermoplastics, which differ in their structure. A distinction is also made between standard and engineering plastics, whereby temperature resistance is the decisive factor here. In addition to mono-plastics, compounds and multi-layer films are also used, which consist of different plastics extruded in layers. Common plastics are the amorphous thermoplastics ABS, PS, PMMA, and PC, as well as the semi-crystalline thermoplastics PP, HD-PE, A-PET, PET-G, and PVC.

Among thermoplastics, there are materials that are easier or more difficult to process. The difficulty of deep drawing depends primarily on the temperature at which the material can be formed, the size of the temperature window, how much the material sags when softened, how well it can be stretched, and how much it shrinks during and after processing. The distinction between amorphous and semi-crystalline materials makes a big difference here. While amorphous plastics generally soften and can be formed at lower temperatures, semi-crystalline plastics remain solid for longer. The crystalline structures only melt at high temperatures, but then very quickly, which means that the window for forming is small. This fact makes the processing of semi-crystalline plastics inherently more difficult.
The necessary machine equipment and tooling technology also play a role, as materials that are drawn at high temperatures require more sophisticated cooling in the mold.

High-impact polystyrene (HI PS), colloquially referred to as PS in thermoforming, is considered the reference plastic because it has very good thermoforming properties in the areas mentioned. On the other hand, PP is considered very difficult to deep-draw, as the high shrinkage of 2% (the deep-drawn part loses 2% of its volume after cooling) and the enormous sag make life difficult for the processor. In some cases, additional machine components are required to counteract the sag.

Deep drawing machines heat the material, perform the forming process, 
cool the material, and remove the finished deep-drawn part.
The process depth, i.e. how many of the main steps in the deep drawing process are covered by the machine, depends on the selected process. Automatic plate machines are single-station machines, which often only cover the heating and forming process itself. After the deep-drawn part has been removed, it is trimmed separately. Roll forming machines are multi-station machines, which means that all processes from heating to forming, cooling, and separating can be carried out one after the other.
Deep drawing machines are equipped with heating and cooling technology and, depending on the degree of sophistication of the machine, pneumatic, hydraulic, and electric drives to carry out the movement sequences of the manufacturing process.

The semi-finished products used in thermoforming, in the form of films and sheets, are sourced from manufacturers of thermoplastic semi-finished products. They extrude films and sheets from granulate of the appropriate plastic types in the desired cut shape, thickness, and color. They can also extrude various additives and color strips into the semi-finished products and fulfill other special requests. It is always very important that the semi-finished products are often extruded to order. Since the extruders have to be set up for a long time before production, there are always minimum order quantities for semi-finished products. Her

The advantages of this process lie in the possibility of manufacturing inexpensive and aesthetically appealing plastic products. Low tooling costs, short lead times, a wide range of materials, high reproducibility, high-quality appearance, and the flexibility of the process make it suitable for a wide range of applications. For quantities ranging from several hundred to 10,000 pieces, thermoforming is usually unbeatable. However, certain geometric requirements must be met, as the tool only has contact with the material on one side, unlike injection molding. These limitations can be circumvented by Design for Manufacturing (DfM) if taken into account early in the development process.

While the areas of application are diverse, at formary we divide them into the following solutions: (1) goods transport and storage, (2) automation, (3) inlays, (4) containers, and (5) covers.

The category goods transport and storage primarily includes storage and transport solutions in the form of trays and workpiece carriers used in industrial environments. These are developed individually for customer products and components and are often used in stacked form in KLTs and cardboard boxes.

The area of automation covers the same field, except that automated loading and unloading is carried out by automation systems and robot technology. The tray therefore has an extended range of functions, additional equipment options (coding, alignment, positioning) and a more in-depth development process.

Inlays are adapted to various containers, in which they are used as form-fitting inserts. These can be drawers, tool cases or folding boxes.

Containers are mainly used as trays for a wide range of industrial applications and for medical purposes.

Covers, or technical deep-drawn parts, are used as housings to protect and enhance the aesthetics of medical and automotive applications.

Yes, thermoformed parts can be fully recycled.

There are two different recycling cycles. The post-industrial cycle

is used in the production of deep-drawn parts by all of our partners. All punching and milling residues are collected and returned to the material cycle. The residues are turned into new granulate, which is then used to produce new films and sheets. The post-consumer cycle cannot be controlled directly by us, as the end consumer is responsible for ensuring that the material is disposed of properly. If the end consumer is a company, all parts can be completely recycled at the end of their life. formary takes back old deep-drawn parts. If the end consumer is a private individual, the material can be disposed of in the yellow bin so that it can be sent to the next recycling company.

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.