Thermoforming Plastic Sheets
Forming from the plastic sheet up to 4000 x 3000mm forming area | up to 15mm initial thickness | Fast prototypes | Surface finishes
Short explanation of forming from plastic sheets
Forming from plastic sheets is used for manufacturing large, voluminous parts.
Parts with a material thickness of 3 mm or more are produced from individual plastic sheets rather than rolls. These sheets can have a thickness of up to 15 mm.
During the forming process, heating and shaping occur sequentially at a single station. The vacuum forming machine operates using both compressed air and vacuum control. Compressed air pre-stretches the material before it is shaped over the forming tool using vacuum suction.
Automation can be integrated using robotic arms and suction grippers to load the plastic sheets into the forming machine and remove the finished parts.
How the forming process works
Plastic sheet is clamped in a frame
Sheet is heated
Material is pre-stretched with compressed air
Tool forms the thermoformed part
Frame opens, thermoformed part is removed
Key facts on forming from plastic sheets
4 x 3 m
50 to > 10.000
1.200mm
15mm
From 4 weeks
Advantages of forming from plastic sheets
Cost savings
Lower project costs compared to metal parts, fiberglass-reinforced plastic (FRP), or small to medium injection molding series.
Suitable for small batches
Depending on the application, forming from plastic sheets is cost-effective from just a few hundred units up to several thousand.
Material variety
Sheet-forming machines process materials directly with texture and color—no post-processing needed.
Unlimited post-processing options
Surface finishing options include grinding, polishing, painting, printing, and electroplating.
Lightweight components
Thermoforming on plastic sheets enables the production of large, thin-walled, and lightweight parts.
Precision cutting
Fast and precise contours, openings, slots, and recesses are achievable with 5-axis CNC milling machines.
Product applications for plastic sheet forming
Transport
- Automotive,
- Electronics,
- Medical Technology,
- Industrial Solutions,
- Consumer Goods
Automation
- Automotive,
- Electronics,
- Industrial Solutions,
- Mechanical Engineering
Boxes
- Medical Technology,
- Mechanical Engineering,
- Consumer Goods
Inlays
- Industrial Solutions,
- Electronics,
- Consumer Goods,
- Cosmetics,
- Medical Technology
Covers
- Automotive,
- Industrial Solutions,
- Medical Technology,
- Consumer Goods,
- Electronics,
- Mechanical Engineering
Available thermoplastics for plastic sheet Forming
The formary network offers plastic sheets in various materials to meet the needs 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 plastic sheet forming machines
The base plate is the first component of the so-called substructure. In sheet-forming machines, the base plate is an integral part of the forming machine and does not need to be separately manufactured when ordering a forming tool.
More information on forming from plastic sheets
Key factors in your cost calculation for forming from plastic sheets
Cycle time
Setup times
Machine fit
Digital control
Preheating
Cooling
Energy Consumption
Data Storage
Undercuts
Quality and tolerances in plastic sheet forming
| Part areas | Relevant points and tolerances | |
|---|---|---|
| Dimensional measurements | Tolerances according to DIN ISO 2768-c or -m | |
| Material thickness | - Semi-finished material: Manufacturers typically allow a tolerance range of up to +/-10% in material thickness. - This must be checked before production to proactively adjust for thickness variations within a tighter tolerance range. - These fluctuations must be considered within the tolerance window. | |
| Trim edge | - Milling: Milled edges are deburred. The precision and cleanliness of the milling cut depend on the chosen milling head size and milling speed. - Knife-cut punching: In knife-cut punching, attention must be paid to whiskers (fine filaments) along the trim contour. - Shear-cut punching: In shear-cut punching, burr formation at the trim edge must be considered. |