Manufacturing Process – Thermoforming from Plastic films
For plastic rolls up to 960 x 650mm forming area | Up to 3mm starting thickness | Various pattern options | Fast production
Thermoforming from Plastic Film – A Quick Overview
Roll-fed thermoforming offers the fastest cycle times in plastic thermoforming, making it ideal for high-volume production and cost-effective products.
This process is specifically designed for small thermoformed parts such as packaging, blisters, and transport trays. Standard forming takes place on a 960 x 650 mm surface, where multi-cavity molds can be used. This maximizes the number of thermoformed parts per machine cycle, significantly reducing production time.
Roll-fed thermoforming machines are often fully automated, from material feeding to stacking finished parts. This ensures high repeatability in product quality. Adjustable preheating and pre-stretching processes further optimize the results.
Achieving sharp, well-defined thermoformed parts depends on multiple factors. Heating, mold design, cooling times, and special components like upper dies all play a crucial role in ensuring precision and efficiency in roll-fed thermoforming.
How does the thermoforming of plastic film work?
Key Facts about Thermoforming of Plastic Film
960 x 650mm
100 to > 1.000.000
150mm
3mm
From 4 weeks
Advantages of Thermoforming Plastic Film
Cost-Effective Unit Prices
For small to medium production runs, thermoforming from plastic roll stock has lower overall costs compared to injection molding or 3D printing.
Fast Cycle Times
Multi-cavity tools and combined forming-punching tools enable quicker cycle times.
Precise Reproducibility
High repeatability and tight tolerances are easily achievable with the right thermoforming equipment.
Material Versatility
Nearly unlimited options for materials, colors, and finishes when thermoforming from plastic roll stock.
Scalable Tooling
Tools can be designed as stand-alone concepts or as base tools with interchangeable inserts.
Recycling
Efficient closed-loop systems enabled by downstream punch grid mills for post-industrial recycling.
Product Applications for Thermoforming from Plastic Roll Stock
Transportation of Goods / Storage of Goods
- Automotive,
- Electronics,
- Medical Technology,
- Industrial Solutions,
- Consumer Goods
Automation
- Automotive,
- Electronics,
- Industrial Solutions
Containers
- Medical Technology,
- Mechanical Engineering,
- Consumer Goods
Interior
- Industrial Solutions,
- Electronics,
- Consumer Goods,
- Medical Technology,
- Food
Covers
- Automotive,
- Industrial Solutions,
- Electronics,
- Consumer Goods,
- Cosmetics,
- Mechanical Engineering,
- Food,
- Medical Technology
Available Thermoplastics for Thermoforming
The formary network offers plastic roll stock in various materials to meet the demands of different industries and applications.
| Material | Application | Price | Temperature restistance | ||
|---|---|---|---|---|---|
 | All-rounder, good mechanical and thermal properties | -40°C – 75°C | |||
 | Modified ABS, weather and UV resistant | -20°C – 90°C | |||
 | Resistant to oils and chemicals, low hardness, good elasticity | -50°C – 85°C | |||
 | Highly heat resistant, highly transparent, electrical insulator | -100°C – 130°C | |||
 | Cost-effective, highly transparent, consumer and food packaging | -10°C – 60°C | |||
 | Modified PET-A, very high mold sharpness and transparency | -40°C – 63°C | |||
 | “Plexiglas”, crystal clear appearance, very rigid/brittle, weather-resistant | -40°C – 70°C | |||
 | Very soft, very stretchy, packaging area | 0°C – 100°C | |||
 | Universally applicable, medium hardness and strength, relatively inexpensive | -20°C – 60°C | |||
| High rigidity, strength, and transparency, resistant to chemicals | -5°C – 65°C |
Tooling Setup for Thermoforming Machines Using Plastic Roll Stock
In forming machines for small plastic parts, plastic rolls are unwound, heated, and fed into the forming station.
To transport the roll material, chains engage with the edges of the heated plastic and move the film through the machine. To prevent the plastic roll from sagging due to heat exposure, the chains apply slight tension to spread it. Additionally, they function as a clamping frame, securing the material during forming and sealing it during vacuum forming. To allow the chain to grip the film edge effectively, the edges are often preheated.
More Information on Thermoforming Plastic Roll
Key Factors in Your Part Cost Calculation for Thermoforming from Plastic Roll
Cycle Time
Setup Time
Product-Specific Machine Equipment
Digital Control
Preheating
Cooling
Energy Consumption
Data Storage
Complex Geometries
Quality and Tolerances in Plastic Roll Thermoforming
| Part Locations | Relevant Points and Tolerances | |
|---|---|---|
| Length Measurements | Tolerances according to DIN ISO 2768-c or -m | |
| Material Thickness | Semi-finished product: Material manufacturers typically have a tolerance range that allows up to +/-10% variation in material thickness. This must be checked by the processor before manufacturing to proactively address thickness variations and respond to narrower tolerance ranges. Variations must be proactively managed within the tolerance window. | |
| Trimming Edge | - Milling: Milling cuts are deburred. The trimming accuracy and cleanliness of the milled edge depends on the size of the selected milling head and the milling speed - Knife-cut punching: With the knife-cut punching process, attention must be paid to angel hairs in the trimming contour - Shear cut punching: When using the shear-cut punching process, attention must be paid to the formation of beards on the trim edge |