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Demand.png",95.37,{"ext":304,"url":406,"hash":407,"mime":307,"name":408,"path":85,"size":409,"width":410,"height":411},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_Df_M_Tool_Webinar_Header_On_Demand_3f760d81b0.png","thumbnail_Df_M_Tool_Webinar_Header_On_Demand_3f760d81b0","thumbnail_DfM-Tool Webinar Header_On Demand.png",39.55,245,138,"Df_M_Tool_Webinar_Header_On_Demand_3f760d81b0",157.42,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDf_M_Tool_Webinar_Header_On_Demand_3f760d81b0.png","2025-07-24T14:52:11.000Z","2026-05-22T10:02:04.515Z","2026-01-08T22:06:32.654Z",{"__component":419,"id":420,"title":421,"text":422,"image":85,"cta_button":423},"page-template.banner",474,"Download guide now for free","Learn how to identify design errors in CAD, avoid costly tool modifications, and achieve production readiness faster.",{"id":424,"visible":425,"label":426,"link":427,"variant":428},3082,true,"Download Whitepaper now","https:\u002F\u002Fshare.hsforms.com\u002F1z0ub-XiHSDm0vRYm2wT00Q8o2u3","secondary",{"__component":430,"id":431,"title":432,"variant":289,"cta_button":85,"blogarticles":433,"style":1505},"page-template.blog-teaser",780,"Additional resources you might find interesting:",[434,953,1167,1332],{"id":435,"documentId":436,"createdAt":437,"updatedAt":438,"publishedAt":85,"locale":10,"title":439,"introduction":440,"content":441,"slug":442,"cover":443,"seo":494,"blog_author":508,"blogcategory":551,"inline_hubspot_form":85,"blocks":911,"localizations":944},349,"kry9z4d9ub1c3foldtl5lm62","2026-01-13T15:51:47.416Z","2026-06-15T17:37:53.252Z","Design for Manufacturing (DfM): Guide to Manufacturing-Oriented Design","With the new Design for Manufacturing analysis from formary, it is now possible to check CAD data for thermoformability in a matter of seconds, allowing potential sources of error to be identified early on before they become costly. Read on to find out what features the DfM software offers and what the Design for Manufacturing principle entails.","\u003Ch2>\u003Cspan style=\"background-color:rgb(255,255,255);color:#005250;\">Design for Manufacturing – The most important facts \u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Design for Manufacturing (DfM) means designing products so that they can be manufactured easily, economically, and with few errors.\u003C\u002Fli>\u003Cli>With a DfM analysis, you can identify manufacturing problems as early as the design phase.\u003C\u002Fli>\u003Cli>The new DfM tool by formary enables an automated analysis of your 3D models quickly, accurately, and free of charge in your browser.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">→ Go directly to DfM Analysis:\u003C\u002Fspan> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is Design for Manufacturing?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cstrong>DfM Meaning:\u003C\u002Fstrong> Design for Manufacturing, Design for Manufacturability (DfM), or “manufacturing-oriented design,” refers to a design approach in which components are created in such a way that they can be produced easily, efficiently, and cost-effectively while maintaining high quality.\u003C\u002Fp>\u003Cp>In short: DfM ensures that from the design stage it is clear how the product can be manufactured later on, helping customers save both time and money.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">How does Design for Manufacturing work?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Design for Manufacturing works by checking already during the design phase whether a component is manufacturable. There are clear manufacturing rules and criteria such as wall thicknesses, radii, or moldability:\u003C\u002Fp>\u003Col>\u003Cli>Analysis of geometry for manufacturability\u003C\u002Fli>\u003Cli>Identification of critical areas (e.g., overly thin wall sections)\u003C\u002Fli>\u003Cli>Adjusting the design for optimization\u003C\u002Fli>\u003Cli>Validation and release for the manufacturing process\u003C\u002Fli>\u003C\u002Fol>\u003Ch3>\u003Cspan style=\"color:#005250;\">The 5 Design for Manufacturing Principles\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Design for Manufacturing is based on five key principles that help solve manufacturing issues early in the design phase.\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Design for Manufacturing Principle\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Application in the Development Process\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Problems Solved by DfM\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>1️⃣ Error prevention in design\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Identify and eliminate potential error sources early\u003C\u002Ftd>\u003Ctd>Fewer complaints, higher quality\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>2️⃣ Manufacturing-oriented design\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Consider appropriate processes and materials\u003C\u002Ftd>\u003Ctd>Improved manufacturability, reduced production costs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>3️⃣ Reducing the number of parts\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Design with as few individual parts as possible\u003C\u002Ftd>\u003Ctd>Less assembly effort, fewer error sources\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>4️⃣ Standardized components\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Use standard parts instead of custom-made ones\u003C\u002Ftd>\u003Ctd>Shorter lead times, lower costs, easier sourcing\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>5️⃣ Modularization of design\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Divide components into interchangeable modules\u003C\u002Ftd>\u003Ctd>Better maintainability, easier variant production\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of Design for Manufacturing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thanks to its core principles, DfM analysis offers numerous benefits:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Early error detection:\u003C\u002Fstrong> Critical areas are identified directly in the CAD model\u003C\u002Fli>\u003Cli>\u003Cstrong>Cost reduction:\u003C\u002Fstrong> Avoidance of expensive rework and complaints\u003C\u002Fli>\u003Cli>\u003Cstrong>More efficient processes:\u003C\u002Fstrong> Fewer queries and delays during development\u003C\u002Fli>\u003Cli>\u003Cstrong>Improved quality:\u003C\u002Fstrong> Better feasibility and reproducibility in series production\u003C\u002Fli>\u003Cli>\u003Cstrong>Planning reliability:\u003C\u002Fstrong> Clear communication with manufacturing and tooling departments\u003C\u002Fli>\u003Cli>\u003Cstrong>Adaptable to different manufacturing processes:\u003C\u002Fstrong> Whether injection molding, 3D printing, or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">vacuum forming,\u003C\u002Fa> DfM supports all common manufacturing methods.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">What Does DfM Analysis Mean for the Thermoforming Process in Practice?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffabdeckung_ac9d53be5c.png\" alt=\"Plastic cover in orange\">\u003C\u002Ffigure>\u003Cp>When designing a plastic thermoformed parts such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">plastic covers\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">plastic containers,\u003C\u002Fa> this means, for example:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Optimizing wall thicknesses\u003C\u002Fstrong> to ensure even material distribution\u003C\u002Fli>\u003Cli>\u003Cstrong>Designing radii\u003C\u002Fstrong> so that they can be thermoformed without issues\u003C\u002Fli>\u003Cli>\u003Cstrong>Building components modularly\u003C\u002Fstrong> to allow for product variants\u003C\u002Fli>\u003Cli>\u003Cstrong>Using standardized mounts or fasteners\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>\u003Cstrong>Considering draft angles\u003C\u002Fstrong> to enable easy removal from the mold\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ For more details on what you need to consider when designing plastic thermoformed parts, see our article on \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\"> Design Guidelines for Plastic Thermoformed Parts.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Challenges and Disadvantages of DfM?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Although Design for Manufacturing offers many benefits, there are typical challenges in practice:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Often requires extensive experience:\u003C\u002Fstrong> Designers must consider complex manufacturing rules\u003C\u002Fli>\u003Cli>\u003Cstrong>Time-consuming manual checks:\u003C\u002Fstrong> Without software tools, wall thicknesses, radii, and draft angles must be analyzed manually\u003C\u002Fli>\u003Cli>\u003Cstrong>Risk of errors:\u003C\u002Fstrong> Human judgment is error-prone and can lead to costly rework\u003C\u002Fli>\u003Cli>\u003Cstrong>Communication problems:\u003C\u002Fstrong> Without clear visualization, misunderstandings can occur between design and tooling departments\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Solution: DfM Analysis of Plastic Thermoformed Parts in Seconds\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Upload your thermoforming part data, and our DfM software will evaluate whether it can be manufactured as designed, or which geometries need to be modified for technical, functional, or cost-related reasons. These modifications can then be carried out either by you or by us.\u003C\u002Fp>\u003Cfigure class=\"image image_resized image-style-side\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDf_M_Analyse_Software_Mockup_5e3c27edb2.webp\" alt=\"DfM-Analyse Software Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Does the DfM Analysis Work?\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>Upload STEP file\u003C\u002Fli>\u003Cli>Automatic analysis in about 60 seconds\u003C\u002Fli>\u003Cli>Color-coded results for:\u003Cul>\u003Cli>Wall thickness distribution\u003C\u002Fli>\u003Cli>Radii\u003C\u002Fli>\u003Cli>Edges and draft angles\u003C\u002Fli>\u003Cli>Stretching ratio\u003C\u002Fli>\u003Cli>Narrow sections and details\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Fol>\u003Cp>Here is a guide on how to use the tool: \u003C\u002Fp>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fyoutu.be\u002Fs6GyeKqi6lw?si=uwqrQH6nYjKsST_V\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of the DfM Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Automated analysis in seconds\u003C\u002Fli>\u003Cli>Color-coded and visually intuitive\u003C\u002Fli>\u003Cli>No waiting times or manual queries\u003C\u002Fli>\u003Cli>Detect errors early and reduce costs\u003C\u002Fli>\u003Cli>Usable directly in the browser\u003C\u002Fli>\u003Cli>No expert knowledge required\u003C\u002Fli>\u003Cli>Provides a basis for smooth coordination with toolmaking\u003C\u002Fli>\u003C\u002Ful>\u003Cp>ℹ️ It is important to note that you still thouroughly check your \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fconstruction-data-in-thermoforming\">construction \u003C\u002Fa>data to avoid potential errors in the later design.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Design for Manufacturing for Plastic Thermoformed Parts – Now Easier Than Ever\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Design for Manufacturing ensures that your products are manufacturable right from the start. With our free DfM analysis, you can check your design in about 60 seconds—for fewer errors, lower costs, and smoother workflows.\u003C\u002Fp>\u003Cp>→ Book your \u003Ca href=\"https:\u002F\u002Fmeetings.hubspot.com\u002Fmoritz-bittner-formary\u002Fdfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=69376d09-d796-4f3c-9d5e-ff6833d70b23\">demo \u003C\u002Fa>now!\u003C\u002Fp>","design-for-manufacturing-guide",{"id":444,"documentId":445,"name":446,"alternativeText":447,"caption":16,"width":363,"height":213,"formats":448,"hash":489,"ext":304,"mime":307,"size":490,"url":491,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":492,"updatedAt":492,"publishedAt":493},2248,"a1i2t0bzmfwznhanhl61lq4z","Blog Banner English.png","Blog Banner English",{"lg":449,"md":454,"sm":459,"xl":464,"2xl":469,"avatar":474,"default":479,"thumbnail":484},{"ext":304,"url":450,"hash":451,"mime":307,"name":452,"path":85,"size":453,"width":165,"height":220},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Flg_Blog_Banner_English_00a8384110.png","lg_Blog_Banner_English_00a8384110","lg_Blog Banner English.png",293.5,{"ext":304,"url":455,"hash":456,"mime":307,"name":457,"path":85,"size":458,"width":157,"height":375},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fmd_Blog_Banner_English_00a8384110.png","md_Blog_Banner_English_00a8384110","md_Blog Banner English.png",166.13,{"ext":304,"url":460,"hash":461,"mime":307,"name":462,"path":85,"size":463,"width":173,"height":381},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsm_Blog_Banner_English_00a8384110.png","sm_Blog_Banner_English_00a8384110","sm_Blog Banner English.png",119.45,{"ext":304,"url":465,"hash":466,"mime":307,"name":467,"path":85,"size":468,"width":147,"height":387},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fxl_Blog_Banner_English_00a8384110.png","xl_Blog_Banner_English_00a8384110","xl_Blog Banner English.png",369.33,{"ext":304,"url":470,"hash":471,"mime":307,"name":472,"path":85,"size":473,"width":212,"height":393},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F2xl_Blog_Banner_English_00a8384110.png","2xl_Blog_Banner_English_00a8384110","2xl_Blog Banner English.png",421.42,{"ext":304,"url":475,"hash":476,"mime":307,"name":477,"path":85,"size":478,"width":310,"height":399},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Favatar_Blog_Banner_English_00a8384110.png","avatar_Blog_Banner_English_00a8384110","avatar_Blog Banner English.png",12.86,{"ext":304,"url":480,"hash":481,"mime":307,"name":482,"path":85,"size":483,"width":233,"height":34},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fdefault_Blog_Banner_English_00a8384110.png","default_Blog_Banner_English_00a8384110","default_Blog Banner English.png",79.34,{"ext":304,"url":485,"hash":486,"mime":307,"name":487,"path":85,"size":488,"width":410,"height":411},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_Blog_Banner_English_00a8384110.png","thumbnail_Blog_Banner_English_00a8384110","thumbnail_Blog Banner English.png",33.41,"Blog_Banner_English_00a8384110",119.07,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FBlog_Banner_English_00a8384110.png","2025-09-17T13:00:36.000Z","2026-01-08T22:06:39.556Z",{"id":495,"open_graph_title":496,"open_graph_description":497,"title":496,"description":497,"open_graph_image":498},2236,"What is Design for Manufacturing (DfM?","Design for Manufacturing: ✓ DfM meaning ✓ DfM advantages ✓ DfM disadvantages ✓ DfM analysis with formary ▶ Read now.",{"id":444,"documentId":445,"name":446,"alternativeText":447,"caption":16,"width":363,"height":213,"formats":499,"hash":489,"ext":304,"mime":307,"size":490,"url":491,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":492,"updatedAt":492,"publishedAt":493},{"lg":500,"md":501,"sm":502,"xl":503,"2xl":504,"avatar":505,"default":506,"thumbnail":507},{"ext":304,"url":450,"hash":451,"mime":307,"name":452,"path":85,"size":453,"width":165,"height":220},{"ext":304,"url":455,"hash":456,"mime":307,"name":457,"path":85,"size":458,"width":157,"height":375},{"ext":304,"url":460,"hash":461,"mime":307,"name":462,"path":85,"size":463,"width":173,"height":381},{"ext":304,"url":465,"hash":466,"mime":307,"name":467,"path":85,"size":468,"width":147,"height":387},{"ext":304,"url":470,"hash":471,"mime":307,"name":472,"path":85,"size":473,"width":212,"height":393},{"ext":304,"url":475,"hash":476,"mime":307,"name":477,"path":85,"size":478,"width":310,"height":399},{"ext":304,"url":480,"hash":481,"mime":307,"name":482,"path":85,"size":483,"width":233,"height":34},{"ext":304,"url":485,"hash":486,"mime":307,"name":487,"path":85,"size":488,"width":410,"height":411},{"id":509,"documentId":510,"createdAt":511,"updatedAt":512,"publishedAt":85,"locale":10,"role":513,"name":514,"email":515,"phone":516,"meeting_url":517,"image":518,"localizations":546},51,"umk62m0sgi9fe20ee90o9b9f","2026-01-16T11:13:10.227Z","2026-01-30T14:36:02.615Z","Marketing and PR Manager","Sarah Guaglianone","sarah.guaglianone@formary.de","015202087894","https:\u002F\u002Fmeetings.hubspot.com\u002Fsarah-guaglianone",{"id":519,"documentId":520,"name":521,"alternativeText":522,"caption":16,"width":173,"height":523,"formats":524,"hash":541,"ext":304,"mime":307,"size":542,"url":543,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":544,"updatedAt":544,"publishedAt":545},1874,"s0go9m7qi1x2yvzea71n71bn","Sarah Guaglianone - Marketing & PR.png","Sarah Guaglianone - Marketing & PR",638,{"avatar":525,"default":530,"thumbnail":536},{"ext":304,"url":526,"hash":527,"mime":307,"name":528,"path":85,"size":529,"width":310,"height":310},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Favatar_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","avatar_Sarah_Guaglianone_Marketing_and_PR_883577361c","avatar_Sarah Guaglianone - Marketing & PR.png",26.2,{"ext":304,"url":531,"hash":532,"mime":307,"name":533,"path":85,"size":534,"width":233,"height":535},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fdefault_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","default_Sarah_Guaglianone_Marketing_and_PR_883577361c","default_Sarah Guaglianone - Marketing & PR.png",340.33,479,{"ext":304,"url":537,"hash":538,"mime":307,"name":539,"path":85,"size":540,"width":182,"height":182},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","thumbnail_Sarah_Guaglianone_Marketing_and_PR_883577361c","thumbnail_Sarah Guaglianone - Marketing & PR.png",40.8,"Sarah_Guaglianone_Marketing_and_PR_883577361c",160.34,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSarah_Guaglianone_Marketing_and_PR_883577361c.png","2025-03-10T12:07:01.000Z","2026-01-08T22:05:48.776Z",[547],{"id":548,"documentId":510,"createdAt":549,"updatedAt":549,"publishedAt":85,"locale":128,"role":550,"name":514,"email":515,"phone":516,"meeting_url":517},6,"2026-01-09T11:19:33.660Z","Marketing und PR Managerin",{"id":552,"documentId":553,"createdAt":554,"updatedAt":555,"publishedAt":85,"locale":10,"title":556,"slug":557,"description":558,"blogarticles":559,"seo":900,"localizations":903},37,"nm4hkxw9ydvlepb5n0fbq8ls","2026-01-13T16:44:17.483Z","2026-01-26T08:25:05.206Z","Thermoformed Parts in Practice","thermoformed-parts-in-practice","All insights into the practice of thermoforming. Useful tips on what to consider. Here you will find entries on all aspects of thermoforming.",[560,569,578,587,596,605,614,623,632,641,650,659,668,677,686,695,704,712,721,730,739,748,757,766,775,784,793,802,803,812,821,830,838,847,855,864,873,882,891],{"id":561,"documentId":562,"createdAt":563,"updatedAt":564,"publishedAt":85,"locale":10,"title":565,"introduction":566,"content":567,"slug":568},362,"r3y5ruu65xv9w55humtuk1ws","2026-01-13T15:51:49.911Z","2026-05-27T11:53:21.024Z","Automation of Production - How Trays Support Automation in Industry 4.0","Trays for automation are workpiece carriers that pass through an automated industrial system or production line, fulfilling various functions along the way.","\u003Ch2>Automation in Industry 4.0 – Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Automation in Industry 4.0\u003C\u002Fstrong> boosts efficiency, flexibility, and quality through networked machines, industrial robots, and sensor technology.\u003C\u002Fli>\u003Cli>Trays, used as workpiece carriers, enable the \u003Cstrong>autonomous transport\u003C\u002Fstrong> of components through all stages of production and support robotics and process optimization.\u003C\u002Fli>\u003Cli>\u003Cstrong>Coded and multifunctional trays\u003C\u002Fstrong> ensure digital data capture, traceability, and adaptability to various production systems.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request an automation tray now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Automation?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In Industry 4.0, automation of production is crucial. It is based on the networking of machines and systems to create a smart factory where processes run autonomously and in real time. Production automation enables the use of modern technologies that make production processes not only more efficient and flexible but also better aligned with individual needs.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFoerderband_mit_Industrierobotern_77c7afd4f6.png\" alt=\"Industrieroboter zur Automatisierung der Produktion\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Technologies are used for Automation?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Technologies like industrial robots, computer-controlled machines (CNC), and sensors improve operational safety and ensure consistently high production quality. In industrial manufacturing, many processes, from production to logistics, can be automated. This autonomy increases efficiency, reduces errors, and is a key element of automation technology. In the following sections, you’ll learn how trays enable production automation.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Processes Can Be Automated in Industrial Production?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Modern manufacturing presents many challenges in automating production, especially when optimizing key processes. Below are some of the central processes that are commonly automated:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Inbound Logistics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Components are delivered just-in-time\u003C\u002Fli>\u003Cli>Packaged in practical units on pallets\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Production\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Components are automatically fed into special \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">plastic trays\u003C\u002Fa> (workpiece carriers)\u003C\u002Fli>\u003Cli>Trays pass through all processing stages and can accommodate different component variants\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Outbound Logistics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Finished parts are transported in precise packaging units\u003C\u002Fli>\u003Cli>Reusable shuttle packaging can be used for return transport\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FWerkstuecktraeger_7ae6aaee4c.png\" alt=\"Trays zur Produktionsautomatisierung\">\u003C\u002Ffigure>\u003Ch2>How are trays used in fully or semi-automated systems?\u003C\u002Fh2>\u003Cp>In automated production systems, trays handle the continuous transport of components, from goods receipt to final removal.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Autonomous circulation:\u003C\u002Fstrong> Empty trays are automatically fed into the system, filled or emptied at the processing stations, and discharged again at the end of the production line.\u003C\u002Fli>\u003Cli>\u003Cstrong>Palletizing systems:\u003C\u002Fstrong> Depending on the type of system, drawer systems, tray stackers, or fully automatic palletizers are used. These systems ensure uninterrupted material flow and precise transfer to robots or conveyor technology.\u003C\u002Fli>\u003Cli>\u003Cstrong>Dimensional and standard adaptation:\u003C\u002Fstrong> The tray dimensions are aligned with conveyor belts, robot gripping ranges, and standardized industrial containers. All common standards are stored in the formary database, so that the tray integrates exactly into existing processes.\u003C\u002Fli>\u003Cli>\u003Cstrong>Optimized handling:\u003C\u002Fstrong> Shape, outer contours, and gripping areas are designed so that palletizing systems and robotics can safely pick up, stack, and position the trays – even at high cycle rates.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Optimal Tray Design for Automation in Production\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>There are important design aspects for plastic trays used in production automation:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Form nests:\u003C\u002Fstrong> Form nests are suitable for different component shapes and stages\u003C\u002Fli>\u003Cli>\u003Cstrong>Packing density:\u003C\u002Fstrong> Efficient utilization of the tray surface\u003C\u002Fli>\u003Cli>\u003Cstrong>Poka-Yoke elements:\u003C\u002Fstrong> Prevent incorrect installation through clear positioning\u003C\u002Fli>\u003Cli>\u003Cstrong>Robot gripper adaptation:\u003C\u002Fstrong> Nest contour aligned with the stroke of the gripper fingers\u003C\u002Fli>\u003Cli>\u003Cstrong>Material & stability:\u003C\u002Fstrong> Suitable for multiple cycles in production\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> If you already have 3D data, you can also visualize it in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>. Simply register for free and get started right away.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_Generator_Mockup_Feature_Fokus_f1c7439336.webp\" alt=\"3D Tray Generator Mockup_Feature Fokus\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Trays Support Further Process Automation\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Industrial robots are key in production automation. Primarily, they are responsible for loading and unloading parts in and out of the tray. The edge contour and wall construction depend on the symmetry of the parts and can be supported both visually and mechanically. To position the parts, elements like Poka-Yoke pins can be added to the tray.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.06%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPoka_Yoke_Ecken_zur_Automatisierung_der_Produktion_a734699f7a.png\" alt=\"Poka-Yoke Ecken zur Automatisierung der Produktion\">\u003Cfigcaption>Poka-Yoke Edges\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Adaptation to the robot\u003C\u002Fh3>\u003Cul>\u003Cli>The gripping point on the component must be selected so that the robot arm can grip safely.\u003C\u002Fli>\u003Cli>Size, weight, and geometry of the component determine the cavity shape in the tray.\u003C\u002Fli>\u003Cli>The nest contour is adapted to the optimal stroke of the gripper fingers.\u003C\u002Fli>\u003Cli>The coating of the gripper jaws is based on the respective pick-and-place task.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Different robot systems\u003C\u002Fh3>\u003Cul>\u003Cli>Simple grippers work with a fixed motion sequence.\u003C\u002Fli>\u003Cli>More complex systems have integrated image processing and distance measurement systems to approach contours and components precisely.\u003C\u002Fli>\u003Cli>Depending on the system used, the permissible tolerance range of the tray varies in interaction with the system.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ For more on the construction of a thermoformed part and what to consider, read \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">Design rules for plastic thermoformed parts.\u003C\u002Fa>  \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does the system capture tray data for production automation?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Automation trays can be encoded so that sensors can capture them and collect essential data. Options include binary detection systems in the tray frame and applying markings such as RFID chips, transponders, or fixed engravings that can be recognized and tracked. More information can be found under “\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-production-automation\">Automation Trays.\u003C\u002Fa>”\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.47%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fautomatisierung_transponder_01_875c07872a.png\" alt=\"Integrierter Transponder am Tray zur Automatisierung der Produktion\">\u003Cfigcaption>Integrated Transponder on the automation tray\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Automation of Industry 4.0 Manufacturing through Trays – A Conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The integration of trays into automated manufacturing processes offers an efficient solution to the challenges faced by modern industries. The adaptability to different manufacturing systems, as well as support for robotics, helps increase efficiency and precision. Ultimately, trays for production automation support and optimize Industry 4.0 in many areas.\u003C\u002Fp>","automation-of-production-with-trays",{"id":570,"documentId":571,"createdAt":572,"updatedAt":573,"publishedAt":85,"locale":10,"title":574,"introduction":575,"content":576,"slug":577},352,"my3ss0y0qmen3dlue8sg3mzu","2026-01-13T15:51:48.023Z","2026-06-02T16:26:18.976Z","Component Safety for Your Small Parts: How Thermoformed Plastic Inserts Ensure Secure Transport","Delicate components require protection against damage to prevent costs and downtime. Thermoformed plastic inserts provide an efficient solution for safe transport and storage. In this article, you will learn how thermoformed inserts optimize component safety.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Safety of small components – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Plastic thermoformed inserts hold delicate components securely in place and protect them from knocks, scratches and moisture.\u003C\u002Fli>\u003Cli>They provide mechanical, chemical and, where required, electrostatic protection for components during transport and storage.\u003C\u002Fli>\u003Cli>The precise design facilitates safe handling and reduces damage during transport across a range of industries.\u003C\u002Fli>\u003Cli>Thanks to their reusability and durability, they offer a cost-effective solution for structural safety.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Order your thermoformed liners now from our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\">online shop!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Component Safety?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cstrong>Definition:\u003C\u002Fstrong> Component safety includes all measures designed to protect sensitive or valuable components from damage. This involves specialized packaging solutions and transport aids that ensure secure handling. Protection can include the following aspects:\u003C\u002Fp>\u003Col>\u003Cli>\u003Cstrong>Mechanical Protection\u003C\u002Fstrong> – Prevents scratches, impacts, dents, or other damage from external forces.\u003C\u002Fli>\u003Cli>\u003Cstrong>Chemical Protection \u003C\u002Fstrong>– Shields components from corrosion, moisture, or harmful chemicals.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">\u003Cstrong>ESD Protection\u003C\u002Fstrong>\u003C\u002Fa> – Prevents damage from electrostatic discharge (ESD), which is especially crucial in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics industry\u003C\u002Fa>.\u003C\u002Fli>\u003C\u002Fol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FBauteile_fuer_Tiefzieheinlagen_e81d4dafad.png\" alt=\"Bauteile für Tiefzieheinlagen\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Thermoformed Plastic Inserts Protect Your Components\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed inserts, also known as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">inlays\u003C\u002Fa>, are produced using the \u003Cstrong>plastic thermoforming process\u003C\u002Fstrong>. Through \u003Cstrong>sheet or roll production\u003C\u002Fstrong>, plastic films are heated and shaped into a mold. The result includes not only inserts but also \u003Cstrong>plastic trays, covers, and containers\u003C\u002Fstrong>.\u003C\u002Fp>\u003Cp>These inserts securely hold products or bulk materials in a custom-fit blister within a container or box. Their precise shape prevents movement, ensuring that sensitive components remain in place. This is especially crucial for delicate parts or products that require a specific orientation during assembly. By securing components, thermoformed inserts prevent transport damage and ensure component safety.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStandard_Tiefzieheinlagen_aus_Kunststoff_b6c50d999e.png\" alt=\"Standard Tiefzieheinlagen aus Kunststoff\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Design features of standard thermoformed inserts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>When designing thermoformed inserts, the following points are taken into account:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Custom-shaped sockets:\u003C\u002Fstrong> Round, square or ribbed, depending on the component geometry.\u003C\u002Fli>\u003Cli>\u003Cstrong>Clamping devices:\u003C\u002Fstrong> Hold sensitive products securely in place.\u003C\u002Fli>\u003Cli>\u003Cstrong>Minimum punch margin:\u003C\u002Fstrong> Ensures a flush finish with the container and prevents slipping.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>These features ensure that components are stored securely and stably in any transport situation.\u003C\u002Fp>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:25.11%;\">\u003Cimg style=\"aspect-ratio:985\u002F835;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FESD_Tiezfieheinlage_zur_Bauteilsicherheit_von_elektronischen_Teilen_0dab016189.png\" alt=\"Tiefzieheinlage\" width=\"985\" height=\"835\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Component Safety for ESD-Sensitive Parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In the electronics industry, protecting delicate components from electrostatic discharge (ESD) is crucial. This electrical discharge can irreparably damage electronic parts, leading to production failures or quality defects.\u003C\u002Fp>\u003Cp>To prevent this, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\u002F3394447\">ESD-Inserts\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD-Trays\u003C\u002Fa> are specially designed to securely store and transport electronic components, ensuring safe handling throughout the logistics chain.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industries That Rely on Thermoformed Inserts for Component Safety\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed plastic inserts serve as \u003Cstrong>protective transport solutions\u003C\u002Fstrong> across various industries. Here are some examples:\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cstrong>Industry\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Fth>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cstrong>Use Case for Thermoformed Inserts\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Automotive\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Protection for body parts, electronic modules, and engine components\u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Electronics\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Safe transport of sensitive circuit boards and semiconductor components\u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Medical Technology\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Secure storage of precision instruments and implants\u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Logistics & Packaging\u003C\u002Fstrong>\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Interlayers for stackable containers and pallets\u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why Are Thermoformed Plastic Inserts Ideal for Component Safety?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed plastic inserts are frequently used as durable inserts in \u003Cstrong>small load carriers (SLCs)\u003C\u002Fstrong> and \u003Cstrong>Euro-standard containers\u003C\u002Fstrong> for small parts that are regularly subjected to heavy use. In cases of intensive mechanical use, such as with heavy tools, the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">material\u003C\u002Fa> of the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fslc-inlays-solution-for-transport-storage\">SLC inserts\u003C\u002Fa> must be particularly robust. Plastic is therefore the preferred material for thermoformed inserts due to its versatility and robustness. \u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_die_sich_in_den_Haenden_befinden_66b91b7e44.png\" alt=\"Kunststoff Granulat\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastic properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Lightweight and durable:\u003C\u002Fstrong> Plastic reduces the overall weight of thermoformed packaging and can withstand even heavy use.\u003C\u002Fli>\u003Cli>\u003Cstrong>Flexible and malleable:\u003C\u002Fstrong> Plastics can be easily heated and moulded into almost any shape, allowing for a wide variety of designs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Shock-absorbing:\u003C\u002Fstrong> Thermoplastics offer good shock absorption, making them ideal for shock-absorbing applications.\u003C\u002Fli>\u003Cli>\u003Cstrong>Chemical and corrosion resistant:\u003C\u002Fstrong> As a rule, most plastics do not react with water, acids or alkalis, making them ideal for use in damp environments and in chemical processes.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Commonly used plastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS\u003C\u002Fa> (polystyrene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa> (acrylonitrile-butadiene-styrene copolymer)\u003C\u002Fli>\u003Cli>and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa> (polypropylene).\u003C\u002Fli>\u003C\u002Ful>\u003Cp>When designing the insert, it is important to consider the requirements that the plastic material must meet in order to ensure that the components are adequately protected during transport.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ In our  \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\"> online shop \u003C\u002Fa>  you will find a selection of over \u003Cb>200 standard thermoformed liners\u003C\u002Fb> for KLTs and Euronorm containers made from PS. Polystyrene is the standard plastic used in thermoforming; it is chemically resistant, has a high degree of hardness and is therefore ideal for transport applications. \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Component safety for your components – with formary Standard thermoformed inserts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Effective component protection is essential for ensuring that products reach their destination safely and undamaged. Do you have any questions or would you like a personalised consultation? Please feel free to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact\u003C\u002Fa> us; we will help you find the ideal transport protection solution.\u003C\u002Fp>","component-safety-for-small-parts",{"id":579,"documentId":580,"createdAt":581,"updatedAt":582,"publishedAt":85,"locale":10,"title":583,"introduction":584,"content":585,"slug":586},340,"hrt0o90vioejy5nuiggttsi8","2026-01-13T15:51:45.749Z","2026-06-02T15:44:19.412Z","ESD Protection for Components in Electronics Manufacturing: Measures, Materials & Solutions","Electrostatic discharge (ESD) can irreparably damage sensitive electronic components and cause high costs. Even very small voltages that are not noticeable to humans can destroy microchips or circuit boards. To reliably protect electronic components during manufacturing, storage, and delivery, various thermoformed parts with ESD protection are used.","\u003Ch2>ESD Protection for Components – Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Plastic thermoformed parts with ESD protection\u003C\u002Fstrong> safeguard sensitive electronic components from electrostatic discharge through conductive and antistatic material additives.\u003C\u002Fli>\u003Cli>ESD-capable thermoformed parts are made from \u003Cstrong>thermoplastics\u003C\u002Fstrong> such as ABS or PS, formed by thermoforming, and also provide surface protection, stability, and reusability.\u003C\u002Fli>\u003Cli>Depending on the \u003Cstrong>application\u003C\u002Fstrong>, ESD containers, electronic housings, or specially shaped trays are used.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request thermoformed part with ESD protection now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What is Electrostatic Discharge (ESD)?\u003C\u002Fh2>\u003Cp>Electrostatic discharge (ESD) refers to the sudden flow of electricity between two differently charged objects. This discharge can occur due to friction, movement, or contact. Particularly at risk are:\u003C\u002Fp>\u003Cul>\u003Cli>Semiconductors\u003C\u002Fli>\u003Cli>Circuit boards\u003C\u002Fli>\u003Cli>Sensors\u003C\u002Fli>\u003Cli>Microchips\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Even voltages of just a few volts can cause damage.\u003C\u002Fp>\u003Ch2>Why is ESD So Dangerous?\u003C\u002Fh2>\u003Cp>The danger of ESD lies in the fact that damage is often invisible. This leads to problems such as:\u003C\u002Fp>\u003Cul>\u003Cli>Components failing immediately\u003C\u002Fli>\u003Cli>Or being weakened over time\u003C\u002Fli>\u003Cli>Quality issues appearing later\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The consequences include production downtime, complaints, and high quality assurance costs. Therefore, it is essential to equip sensitive electronic components in manufacturing with ESD protection.\u003C\u002Fp>\u003Ch2>What ESD Protection Measures Are There?\u003C\u002Fh2>\u003Cp>Effective ESD protection is always based on a holistic concept:\u003C\u002Fp>\u003Ch3>1. ESD Protection at the Workplace\u003C\u002Fh3>\u003Cul>\u003Cli>Conductive table mats\u003C\u002Fli>\u003Cli>Grounding systems\u003C\u002Fli>\u003Cli>ESD wrist straps\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>2. ESD Protective Clothing\u003C\u002Fh3>\u003Cul>\u003Cli>Antistatic clothing\u003C\u002Fli>\u003Cli>ESD shoes\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>3. Thermoformed Parts with ESD Protection\u003C\u002Fh3>\u003Cp>Various solutions are used here:\u003C\u002Fp>\u003Ch4>ESD Transport Packaging\u003C\u002Fh4>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">ESD transport packaging\u003C\u002Fa> protects sensitive electronic components from electrostatic discharge during storage and shipping. Includes bags, foams, or boxes with antistatic or conductive properties, ensuring safe delivery without damage.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FESD_Werkstuecktraeger_2a7999d0b0.jpg\" alt=\"ESD Werkstückträger\" width=\"640\" height=\"640\">\u003C\u002Ffigure>\u003Ch4>Electronic Housings\u003C\u002Fh4>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">Electronic or ESD housings\u003C\u002Fa> provide a safe environment for sensitive components. They prevent electrostatic charging and also protect against mechanical stress, dust, and moisture. That's essential for long-term functional reliability.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FElektronikgehaeuse_aus_Kunststoff_fuer_Elektronik_und_Halbleitertechnologie_9e632f28e3.jpg\" alt=\"Elektronikgehäuse aus Kunststoff mit Deckel\" width=\"640\" height=\"640\">\u003C\u002Ffigure>\u003Ch4>ESD Containers\u003C\u002Fh4>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-esd-containers\">ESD containers\u003C\u002Fa> are used for storage and internal transport of electronic components. Made of conductive plastics and often compatible with standardized logistics systems like KLTs or Euro containers, enabling efficient and safe handling.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1920;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F0097_bit_002_formary_prod_gall_wanne_890d54e8b0.jpg\" alt=\"Roter Tiefziehbehälter aus Kunststoff mit schmaler Passform\" width=\"1920\" height=\"1920\">\u003C\u002Ffigure>\u003Ch4>ESD Trays\u003C\u002Fh4>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD trays\u003C\u002Fa> are specially shaped carriers that hold components precisely in place while protecting them from electrostatic discharge. Ideal for automated processes due to precise positioning and easy handling. Their \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fstacking-methods-for-trays\">stackability\u003C\u002Fa> ensures efficient use of space.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:50%;\">\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fbranchen\u002Felektronik-halbleitertechnologie\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FESD_Tray_9be91e6c40.jpg\" alt=\"ESD Trays in der Elektronikbranche\" width=\"640\" height=\"640\">\u003C\u002Fa>\u003C\u002Ffigure>\u003Ch2>How Does ESD Protection Work in Electronics Manufacturing?\u003C\u002Fh2>\u003Cp>ESD protection is ensured through material composition:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Electrical conductivity:\u003C\u002Fstrong> Additives such as carbon black or graphite make plastics conductive, allowing electrical charges to dissipate efficiently.\u003C\u002Fli>\u003Cli>\u003Cstrong>Antistatic effect:\u003C\u002Fstrong> Prevents static charges from forming on surfaces.\u003C\u002Fli>\u003Cli>\u003Cstrong>Surface protection:\u003C\u002Fstrong> Smooth, treated surfaces protect against scratches and reduce dust or particle adhesion, which could promote static charging.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>What Materials Are Used for ESD Thermoformed Parts?\u003C\u002Fh2>\u003Cp>The basis is modified thermoplastics. Common materials include:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS \u003C\u002Fa>(Acrylonitrile Butadiene Styrene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS \u003C\u002Fa>(Polystyrene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC \u003C\u002Fa>(Polycarbonate)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fhd-pe-plastic\">HD-PE\u003C\u002Fa> (High-Density Polyethylene)\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ Interested in more information about thermoplastics? Our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\"> material guide for plastic thermoformed parts \u003C\u002Fa> provides insights into the world of thermoplastics, compounds, and additives.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>How Are ESD Thermoformed Parts Manufactured?\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Material preparation:\u003C\u002Fstrong> Plastic granules are mixed with additives and antistatic agents during \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">extrusion.\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Cstrong>Forming:\u003C\u002Fstrong> The plastic is heated and shaped during \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoforming.\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Cstrong>Quality control:\u003C\u002Fstrong> Final products are tested for conductivity, antistatic properties, and mechanical stability.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>Applications of ESD Protection Solutions\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">\u003Cstrong>Electronics manufacturing:\u003C\u002Fstrong>\u003C\u002Fa> For transporting and storing semiconductors, circuit boards, and chips between production steps.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">\u003Cstrong>Automotive:\u003C\u002Fstrong>\u003C\u002Fa> Protects sensitive control units and sensors during production and delivery.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">\u003Cstrong>Medical technology:\u003C\u002Fstrong>\u003C\u002Fa> Diagnostic devices and components also require high ESD protection.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Areas of Use For ESD Plastic Thermoformed Parts \u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">Areas of application for plastic parts with ESD protection\u003C\u002Fp>\u003C\u002Fth>\u003Cth>\u003Cp style=\"text-align:center;\">Typical components that require plastic parts with ESD protection\u003C\u002Fp>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Electronics manufacturing \u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Semiconductors, printed circuit boards \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Automotive\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Control units, sensors \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Medical and laboratory technology\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Diagnostic chips, modules \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>Advantages of Thermoformed Parts with ESD Protection\u003C\u002Fh2>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:22.83%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FWarentransport_mit_ESD_Trays_a0593b0c02.png\" alt=\"Warentransport mit ESD Trays.png\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Ch3>1. Durability\u003C\u002Fh3>\u003Cp>Thermoformed parts made of plastic are characterized by high stability and resistance. They are designed for long-term use in production and logistics and withstand even demanding conditions. ESD-resistant thermoformed parts are resistant to:\u003C\u002Fp>\u003Cul>\u003Cli>Impacts\u003C\u002Fli>\u003Cli>Vibrations\u003C\u002Fli>\u003Cli>Moisture\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>2. Customization\u003C\u002Fh3>\u003Cp>Thermoformed parts can be precisely tailored to the geometry and requirements of the respective components. This ensures optimal protection and secure positioning. They offer:\u003C\u002Fp>\u003Cul>\u003Cli>Custom-fit cavities (trays)\u003C\u002Fli>\u003Cli>Secure fixation of components\u003C\u002Fli>\u003Cli>Adaptable for automated processes\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:22.03%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGestapelte_ESD_Trays_f91070dd07.png\" alt=\"Gestapelte ESD Trays\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Ch3>3. Efficient Logistics\u003C\u002Fh3>\u003Cp>Through their well-designed construction, thermoformed parts enable efficient handling along the entire value chain – from production to transport. ESD trays, for example, are ergonomically designed and can be equipped with integrated handles that enable easy gripping and transport.\u003C\u002Fp>\u003Ch3>4. Reusability\u003C\u002Fh3>\u003Cp>ESD thermoformed parts are a more sustainable option compared to disposable packaging, as they can be designed as reusable packaging. This reduces waste and the need for disposable materials such as cardboard or foam.\u003Cbr>Additionally, thermoformed parts in ESD versions can be recycled at the end of their lifecycle to further improve resource efficiency.\u003C\u002Fp>\u003Chr>\u003Ch2>Conclusion: The Right ESD Protection Determines Quality\u003C\u002Fh2>\u003Cp>Effective ESD protection is crucial for the reliability of electronic components. While grounding and protective clothing are important, the right packaging or housing also plays a key role.\u003C\u002Fp>","esd-trays",{"id":588,"documentId":589,"createdAt":590,"updatedAt":591,"publishedAt":85,"locale":10,"title":592,"introduction":593,"content":594,"slug":595},365,"t8cdf4kf19se6cjzzzao0d9i","2026-01-13T15:51:50.468Z","2026-06-02T17:11:12.274Z","Determining the Mold Nests of Your Workpiece Carrier","Mold nests or cavities can be diverse: rectangular, round, custom-shaped, tracks, ribs, or domes. So how is it decided which mold nest is the right one? More on this in the article.","\u003Ch2>Form Nests for Your Plastic Tray - Key Points\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Form nests\u003C\u002Fstrong> (cavities) are custom-fit recesses in the workpiece carrier that fix and protect components during transport, storage and handling.\u003C\u002Fli>\u003Cli>\u003Cstrong>Form design\u003C\u002Fstrong> influences packing density, ergonomics, automation capability and tool costs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Requirements\u003C\u002Fstrong> such as minimum distances, draft angles and gripper cutouts must be considered early in the design phase.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Upload your 3D component in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>: The form nest is automatically adapted to your data.\u003C\u002Fp>\u003Chr>\u003Ch2>What are form nests and cavities?\u003C\u002Fh2>\u003Cp>Form nests are cavities that accommodate the component. Cavity is derived from the Latin \"cavum\" and means hollow. Simply put, form nests are recesses in the workpiece carrier that ensure safe transport of the component and simplified loading and unloading of the tray.\u003C\u002Fp>\u003Ch3>Why are form nests so important?\u003C\u002Fh3>\u003Cp>The shape of the cavity that accommodates the component is in many cases the critical point in functionality. Whether for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">inlays\u003C\u002Fa>, blister packs, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">trays\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-a-workpiece-carrier\">workpiece carriers\u003C\u002Fa> – how well the cavity is adapted to the product determines efficiency and safety during handling, transport and storage.\u003Cbr>Form nests: Different nest contours\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:54.76%;\">\u003Cimg style=\"aspect-ratio:1169\u002F1345;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTypes_of_nests_graphic_ceac375518.webp\" alt=\"Types of nests graphic\" width=\"1169\" height=\"1345\">\u003Cfigcaption>Form Nests: Different Nest Contours\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>What requirements must form nests meet?\u003C\u002Fh2>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Foptimizing-intralogistics\">intralogistics\u003C\u002Fa> and extralogistics, cost optimization is paramount. Important factors include:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Maximum packing density:\u003C\u002Fstrong> The goal is to achieve economical transport volume by placing the maximum possible number of components per tray.\u003C\u002Fli>\u003Cli>\u003Cstrong>Universal nests:\u003C\u002Fstrong> Costs can be saved if as many different components as possible can be transported in a universal tray. This means fewer tray variants, lower investments and reduced handling effort. In this case, the form nests are designed as universal nests.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>What influences the maximum packing density of form nests and cavities?\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>User specifications:\u003C\u002Fstrong> Minimum distance nest-to-nest and nest-to-outer edge for ergonomic handling. Components should be easily removed from the cavity or trays should be able to be quickly placed in a container.\u003C\u002Fli>\u003Cli>\u003Cstrong>Draft angles:\u003C\u002Fstrong> Form nests require a draft angle of 2–5° for ejection in the thermoforming process so the tray can be easily lifted off the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa>.\u003C\u002Fli>\u003Cli>\u003Cstrong>Automation requirements:\u003C\u002Fstrong> Edge geometry, gripper technology, nest depth and positioning. Maximum packing density is always the result of the equation from the specifications above.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>How are universally usable form nests designed?\u003C\u002Fh2>\u003Cp>When investing in the development of a new transport tray, universal tray design is often required. Different component variants or component families can be transported in a universal tray.\u003Cbr>This saves tool costs during cavity production that would otherwise be incurred for each tray variant. This means the form nests must be adapted to different components.\u003C\u002Fp>\u003Ch3>What must be considered when developing universal form nests?\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>The position:\u003C\u002Fstrong> If a horizontal position of the components is not possible due to different dimensions, much space can be wasted.\u003C\u002Fli>\u003Cli>\u003Cstrong>Unequal outer dimensions and\u002For contours:\u003C\u002Fstrong> The contours must be approximately correct, otherwise it becomes difficult.\u003C\u002Fli>\u003Cli>\u003Cstrong>Sensitive areas:\u003C\u002Fstrong> If areas at different points of the components must be recessed, it is often difficult to find a middle ground.\u003C\u002Fli>\u003Cli>\u003Cstrong>Introducing components via different levels:\u003C\u002Fstrong> Steps and tight contours are difficult to thermoform with some materials such as polycarbonate.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>How are the form nests adapted 100% to the component?\u003C\u002Fh2>\u003Cfigure class=\"image image-style-side\">\u003Cimg style=\"aspect-ratio:312\u002F312;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFormnester_von_Kunststofftrays_b2f1c00a99.svg\" alt=\"Formnester von Kunststofftrays\" width=\"312\" height=\"312\">\u003C\u002Ffigure>\u003Cp>A cavity is \u003Cstrong>always\u003C\u002Fstrong> aligned to the original component. This is done using the CAD data of the components, a component sample, or an existing tray.\u003C\u002Fp>\u003Ch3>CAD Data\u003C\u002Fh3>\u003Cp>Creating data via the CAD data of the component is best for both customer and formary: On one hand, we can optimally measure CAD data from all sides. No time-consuming iterations in data adjustment are needed.\u003Cbr>Second, we can adjust details virtually in advance, such as the distance between component and nest inner wall. Before creating the data, we will of course have you sign a confidentiality agreement \u002F non-disclosure agreement.\u003C\u002Fp>\u003Cblockquote>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>, the form nests are automatically adapted to your component data.\u003C\u002Fp>\u003C\u002Fblockquote>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTray_Gen_Handling_Mockup_2db8160d89.webp\" alt=\"Tray Gen Handling Mockup\">\u003C\u002Fp>\u003Ch3>Component Sample\u003C\u002Fh3>\u003Cp>The second option is to create the form nest data based on a component sample. Depending on the structure of the component, we can either measure manually or use an optical measuring device.\u003C\u002Fp>\u003Ch3>Existing Tray\u003C\u002Fh3>\u003Cp>As a third option, we can also reverse-engineer the data based on an old tray sample, i.e. we measure the part with a Faro Arm. An existing disadvantage is that any imperfections on the tray surface are also transferred, which then exist in the data model.\u003Cbr>It is always important that all other requirements such as tolerance of centering points (for automation trays), grid dimensions and desired dimensions on the nest bottom are communicated. The more details coordinated in advance, the more error-free the data design will be.\u003C\u002Fp>\u003Ch2>Can I test the fit of the cavity before tool creation?\u003C\u002Fh2>\u003Cp>The answer is yes. After the nest design has been created in the CAD program, functionality can be tested via various sample options (see also \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fprototyping\">Prototypes\u003C\u002Fa> or our blog post \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Frapid-prototyping-in-thermoforming\">Rapid Prototyping\u003C\u002Fa>)\u003C\u002Fp>\u003Ch4>Sample Options\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Cstrong>3D printing:\u003C\u002Fstrong> fast, inexpensive, but limited validity.\u003C\u002Fli>\u003Cli>\u003Cstrong>Ureol thermoforming:\u003C\u002Fstrong> realistic, tests material behavior directly in the thermoforming process.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The choice therefore depends on\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Speed\u003C\u002Fstrong> of the required results,\u003C\u002Fli>\u003Cli>\u003Cstrong>Validity\u003C\u002Fstrong> compared to series production,\u003C\u002Fli>\u003Cli>available \u003Cstrong>budget\u003C\u002Fstrong>.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FComparison_Ureol_3_D_print_englisch_8417dbfdda.webp\" alt=\"Comparison Ureol 3D print englisch\">\u003C\u002Fp>\u003Cp>Sample options for form nests\u003C\u002Fp>\u003Ch3>What happens if the components don't fit in the form nests?\u003C\u002Fh3>\u003Cp>The form nests can be adjusted depending on the tool design:\u003C\u002Fp>\u003Cfigure class=\"table\" style=\"width:auto;\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Tool Design\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Adjustment of form nests in this direction possible\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Adjustment of form nests in this direction not possible\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Negative tool\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cp>Deepening the form nests\u003C\u002Fp>\u003Cul>\u003Cli>Make form nests larger all around to create more air between nest and component\u003C\u002Fli>\u003Cli>Set form nests deeper to recess components deeper in the nest\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003Ctd>Raising the form nests\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Positive tool\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cp>Raising the nests\u003C\u002Fp>\u003Cul>\u003Cli>Set form nests tighter all around to reduce air between component and nest walls\u003C\u002Fli>\u003Cli>Raise nest bottom to position parts closer to the nest edge, or even to protrude (e.g. for better gripper positioning) \u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003Ctd>Deepening the form nests\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Form Nests and Cavities - A Conclusion\u003C\u002Fh2>\u003Cp>The correct design of form nests determines \u003Cstrong>packing density, component protection and efficiency\u003C\u002Fstrong> in transport and production. Those who consider early on requirements such as minimum distances, draft angles and automation parameters save time and costs and increase process reliability.\u003C\u002Fp>\u003Cp>Still have questions? Write to us now in the live chat or call us: 07191 9525170.\u003C\u002Fp>","how-to-determine-tray-cavities",{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},355,"nz5g6k8re0g3v1tfg9e9ppvl","2026-01-13T15:51:48.617Z","2026-06-02T16:55:30.132Z"," Design Guidelines for Plastic Thermoformed Parts – Top 13 Tips for Plastic-Optimized Construction","Plastic thermoforming is shaped by factors like material quality, temperature, pressure, speed, and tool geometry. With the right design principles, you can prevent errors in CAD and production. formary has gathered key tips to help you optimize your thermoformed parts.\n","\u003Ch2>\u003Cspan style=\"color:#005250;\">Design guidelines for the manufacture of plastic thermoformed parts – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Radii & draft angles:\u003C\u002Fstrong> Large radii (at least 1.5 mm) and draft angles (>2°) facilitate deep drawing and prevent creasing and material tears.\u003C\u002Fli>\u003Cli>\u003Cstrong>Forming ratio & wall thickness:\u003C\u002Fstrong> The ratio of height to width affects material stretching; the initial thickness and the desired wall thickness must be calculated at an early stage.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoforming-friendly geometry:\u003C\u002Fstrong> Take into account transitions, undercuts, tolerances and material shrinkage to optimise quality, demouldability and production costs.\u003C\u002Fli>\u003C\u002Ful>\u003Cblockquote>\u003Cp>\u003Ci>→ Do you already have CAD data that you’d like to check for deep-drawability? \u003C\u002Fi>Click here for the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis\u003C\u002Fa>\u003C\u002Fp>\u003Cp>→ Need a quick 3D tray design? Click here for the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>\u003C\u002Fp>\u003C\u002Fblockquote>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the key design principles to follow when designing deep-drawn parts?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The key design rules for plastic deep-drawn parts are:\u003C\u002Fp>\u003Cul>\u003Cli>sufficiently large radii to prevent cracks\u003C\u002Fli>\u003Cli>Wall angles for safe demoulding\u003C\u002Fli>\u003Cli>a suitable forming ratio for controlling the wall thickness\u003C\u002Fli>\u003Cli>reduced undercuts for easy manufacturing\u003C\u002Fli>\u003Cli>design tailored to the material to prevent warping\u003C\u002Fli>\u003C\u002Ful>\u003Cp>If these design guidelines for plastic deep-drawing are followed, quality, costs and process reliability can be significantly improved. You will find more details on this in the following sections. \u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">1. Design Rule: Radii in Plastic Thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>When designing plastic parts, it is important to always incorporate the largest possible radii in order to improve stretchability. Deep-drawn parts should always be manufactured with a minimum radius of 1.5 mm. \u003C\u002Fp>\u003Cp>When it comes to the tool side, a minimum radius is required; as a very rough rule of thumb (since this depends on many parameters), this should not be less than the original thickness of the material.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_801d30d937.png\" alt=\"Radii in Plastic Thermoforming\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Dealing with sharp edges\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>If sharp edges are required, ensure that the design of the plastic parts includes a fillet radius that is at least as large as the original thickness of the material. If the fillet radius is set smaller, the parts cannot be deep-drawn, or can only be done so with great difficulty. Furthermore, costs will increase due to longer tool milling times.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> \u003Cb>Note:\u003C\u002Fb> The radii appear even larger on the deep-drawn part than on the die itself. For both positive and negative dies, when specifying the smallest possible radii, the key consideration is to ensure that the material fits as snugly as possible into the corners. The radius on the side facing away from the die is determined by the radius of the die side, as well as the material type, the material stretch and the material thickness.      \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">2. Design Rule: Draft Angles\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The angle between the vertical part wall and the direction of demoulding is known as the demoulding angle. As the choice of demoulding angles affects the geometry of the deep-drawn part, the angles of the demoulding angles must be determined at an early stage and incorporated into the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fconstruction-data-in-thermoforming\">design data\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_45961b91ba.png\" alt=\"Draft Angles\">\u003C\u002Ffigure>\u003Cp>Design vertical walls with draft angles to ensure easy demolding without visible surface defects.\u003C\u002Fp>\u003Cp>ℹ️ \u003Cstrong>Recommended Draft Angles:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>General recommendation: >2°\u003C\u002Fli>\u003Cli>Industry standard for negative molds: 1.5 - 2°\u003C\u002Fli>\u003Cli>Industry standard for positive molds: 4 - 6°\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">3. Design Rule: Forming Ratio and Wall Thickness\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The forming ratio describes the relationship between the height and width of the formed area. Since the material is stretched into the mold, it becomes thinner during the process. The forming ratio depends on the tool geometry and final part shape.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.06%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FUmformverhaetlnis_bei_der_Konstruktion_von_Tiefziehteilen_65263b290b.png\" alt=\"Umformverhätlnis bei der Konstruktion von Tiefziehteilen\">\u003C\u002Ffigure>\u003Cp>The resulting wall thickness can be roughly calculated using the following formula:\u003C\u002Fp>\u003Cp>\u003Cstrong>d₂ = (F₁ \u002F F₂) × d₁\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Where:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>F₁\u003C\u002Fstrong> = Area of the material blank (excluding clamping edge)\u003C\u002Fli>\u003Cli>\u003Cstrong>F₂\u003C\u002Fstrong> = Surface area of the final thermoformed part\u003C\u002Fli>\u003Cli>\u003Cstrong>d₁\u003C\u002Fstrong> = Initial material thickness\u003C\u002Fli>\u003Cli>\u003Cstrong>d₂\u003C\u002Fstrong> = Final wall thickness\u003C\u002Fli>\u003C\u002Ful>\u003Cp>ℹ️ More details on radii, draft angles, and forming ratios can be found in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Ftolerances\">tolerances \u003C\u002Fa>section.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">4. Design Rule: Positive vs. Negative Forming and Wall Thickness\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The further or deeper the material is stretched into the tool during thermoforming, the thinner the remaining wall thickness becomes. Typically, the wall thickness to be achieved is determined, and then calculated backwards (see point 3) to determine how thick the starting material must be (so-called \"reverse engineering\").\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Stretch & Draw Ratio\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The stretch or draw ratio in thermoforming describes the length ratio of the material in the side profile (the initial thickness) and the thermoformed part. Generally: Positively formed parts result in a smaller and therefore more advantageous stretch ratio than negatively drawn parts with the same contour.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_902be0c5b9.png\" alt=\"Negative Forming\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Important Rules During the Forming Process\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Due to the viscoelastic behavior of thermoplastics during stretching, some rules of thumb must be observed during the forming process when designing plastic parts:\u003C\u002Fp>\u003Cul>\u003Cli>The colder the semi-finished product during stretching, the greater the force required to stretch it\u003C\u002Fli>\u003Cli>The faster the deformation speed, the greater the force required to stretch it\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Positive Forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>With negatively formed parts, the weak point of the thermoformed part after forming is therefore in the base area, as material is stretched from the edge into the bottom of the tool cavity. The material thins out in the process.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_d0fda1fcc0.png\" alt=\"Negative formed mold vs positive shaped mold\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Negative Forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>With positively formed parts, the weak point of the thermoformed part is at the edge, as the material first touches the positive tool at the base area of the future thermoformed part, thinning out the edge area downwards. Initial thicknesses chosen too thin and a poor forming ratio, i.e., the relation of opening width to opening depth, further exacerbate the negative effect.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tip: \u003C\u002Fstrong>If you are unsure whether your component is designed for thermoforming, we are happy to support you in the design and optimization of your construction with our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis. \u003C\u002Fa>→ Book a \u003Ca href=\"https:\u002F\u002Fmeetings.hubspot.com\u002Fmoritz-bittner-formary\u002Fdfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=3a844e4f-8d79-41c2-96a8-7b643ef3125b\">demo\u003C\u002Fa> now.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">5. Design Rule: Material Stretching in Cavities\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>For negative-formed cavities, the \u003Cstrong>depth-to-width ratio should not exceed 1.5:1\u003C\u002Fstrong>. A greater depth results in significant thinning, increasing the risk of rupture at the bottom edges.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:27.29%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMaterialverstreckung_bei_der_Konstruktion_von_Tiefziehteilen_8ae1a4a0ac.png\" alt=\"Materialverstreckung bei der Konstruktion von Tiefziehteilen\">\u003C\u002Ffigure>\u003Cp>The table explains the possibilities of different pull ratios for negative and positive shapes:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Forming Ratios for Negative and Positive Forms\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Depth-to-Width Ratio\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Positive Forming\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Negative Forming\u003C\u002Fstrong>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>0.3:1\u003C\u002Ftd>\u003Ctd>Possible\u003C\u002Ftd>\u003Ctd>Possible\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>0.5:1\u003C\u002Ftd>\u003Ctd>Possible\u003C\u002Ftd>\u003Ctd>Needs punch assistance\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>1:1\u003C\u002Ftd>\u003Ctd>Possible\u003C\u002Ftd>\u003Ctd>Needs punch assistance\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>1.5:1\u003C\u002Ftd>\u003Ctd>Material distortion at the limit\u003C\u002Ftd>\u003Ctd>Material distortion at the limit\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>2:1\u003C\u002Ftd>\u003Ctd>Must be tested; cannot be simulated\u003C\u002Ftd>\u003Ctd>Must be tested; cannot be simulated\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">6. Design Rule: Transition Contours\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>As already mentioned: In thermoforming design with plastics, it is essential to avoid small radii. Especially with precisely fitting component cavities, nests can be designed to be much more thermoformable with softened contours while maintaining full functionality.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Improved formability through softened contours\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Figure 1 shows a cavity contour that is difficult to thermoform, while Figure 2 shows a softened contour that can be formed easily. By softening the draft angles and radii, the thermoformed part can be drawn more easily, which increases quality. Additionally, this minimizes the risk of tearing and guarantees higher reproducibility.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FScharfer_Hoehenuebergang_ist_schwerz_zu_ziehen_und_kann_zu_Faltenbuldung_fuehren_6624589464.webp\" alt=\"contour formability mockup\">\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Benefits for production and costs\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Ultimately, the cycle times are also shorter, which results in a generally welcome reduction in the unit price. Transitions from edge contours or stepped areas can also be smoothed out using chamfers.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Risks associated with small radii and possible solutions\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>If the radii are too small, there is always a risk of creasing during deep-drawing, particularly with positive moulds. To prevent creasing, ribbed transitions can also be incorporated into the plastic design to ensure that any creases that do occur during positive deep-drawing are at least controlled.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFalten_gezielt_bei_der_Konstrukion_von_Kunststoff_Tiefziehteilen_einsetzen_466f8d330d.png\" alt=\"Faltenbildung gezielt konstruieren bei Kunststoffteilen\" width=\"1920\" height=\"1080\">\u003Cfigcaption>Creasing caused by subtle ribbing\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">7. Design Rule: Undercuts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Undercuts are features that prevent the part from being easily removed from the deep-drawing die. Unlike in injection moulding, there is no second die half, so they make demoulding more difficult.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tips:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Avoid undercuts where possible, or reduce them to a level that allows for deep drawing.\u003C\u002Fli>\u003Cli>Undercuts are often unavoidable in stacked components or clamping arrangements, so careful design is required.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n\u003Ch4>ℹ️ Is your component suitable for deep-drawing?\u003C\u002Fh4>      \n\u003Cp> Many design flaws originate in the CAD model and lead to higher costs or quality issues later on. We review your design and provide you with specific suggestions for optimisation to ensure cost-effective and reliable production.    \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">8. Design Rule: Shrinkage During Processing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Bear in mind that processing shrinkage is a key factor in the design of a plastic deep-drawn part, as it affects the final dimensions and shape. After demoulding, the part shrinks further due to the material’s behaviour. This shrinkage varies depending on the material and can continue for up to 24 hours even after the part has cooled. In the case of semi-crystalline thermoplastics in particular, post-shrinkage never stops and the part may continue to shrink over time.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Measures to counteract processing shrinkage\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Plan the tool size taking shrinkage into account.\u003C\u002Fli>\u003Cli>Carry out a sample test before production begins.\u003C\u002Fli>\u003Cli>\u003Cstrong>Factors:\u003C\u002Fstrong> choice of material, demoulding temperature, extrusion and internal stresses.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">9. Design Rule: Thermoformable Tolerances\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Deep-drawn parts are designed for most industrial and packaging applications with a tolerance of +\u002F- ~1 mm. This corresponds to the tolerance range according to ISO 2768-c for the 120 to 400 mm length dimensions commonly used in this product area.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_fb44b4374a.png\" alt=\"Thermoformable Tolerances\">\u003C\u002Ffigure>\u003Cp>Forming tighter tolerances usually involves additional costs. These are due to longer demolding times, greater manufacturing costs, and\u002For longer cycle times.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ It is important not to set tolerances unnecessarily tight: the motto \u003Cb>“As large as possible, as small as necessary”\u003C\u002Fb> serves as a general guideline in the design manual.     \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">10. Design Rule: Fastening Points in Assemblies\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Fixing points are required to assemble various deep-drawn parts or assemblies. Many fastening technology options are used to securely close deep-drawn parts. These must be carefully considered from the outset to ensure that the design is suitable for plastics. Depending on the mechanical load, the frequency of opening and closing, and the stability of the connection, various options are available for achieving a force-fit connection.\u003C\u002Fp>\u003Cp>In permanently force-fit connections, screws or rivets are often attached to the deep-drawn parts at the transition points between two parts in order to achieve a connection.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_52b2fb3969.png\" alt=\"Fastening Points in Assemblies\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">11. Design Rule: Stacking Design\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>If your thermoformed part is to be stacked, this must be taken into account at an early stage of the design process to ensure that sufficient space is left for stacking. Several factors are key when selecting the appropriate \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fstacking-methods-for-trays\">stacking technique\u003C\u002Fa>:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Initial material thickness\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The choice of stacking method for a thermoformed part depends primarily on the part’s rigidity and the material’s sliding properties. The thicker the material (which is often the case with reusable trays), the easier it is to stack. The poorer the material’s sliding properties, the better the static friction, and consequently the easier it is to stack.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensitivity of the products\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>If the components are not allowed (or should not) be stacked on top of one another, but a gap of a few millimetres must be maintained, a higher-quality stacking technique is required. The reason for this is that the stack of thermoformed parts is self-supporting, meaning that the weight of the trays and their contents must be borne by the tray surface without any additional supports.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Urgency of the timetable\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Complex stacking techniques involving movable stacking elements require the use of a flap mould. Manufacturing such a mould is more time-consuming than producing a relatively simple undercut stacking mould.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">12. Design rule for thermoformed plastic parts: Material selection\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Softer plastics exhibit \u003Cstrong>greater deformation\u003C\u002Fstrong> and higher processing shrinkage after demolding. Materials with high hardness and rigidity are automatically in a better tolerance group in terms of accuracy.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ You can find out more about plastics, their properties and their impact on the overall costs of deep-drawing in our white paper \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\">Material Guide for Plastic Deep-Drawn Parts\u003C\u002Fa>. \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">13. Additional tip: Optimally positioned engravings\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>If you require markings on the thermoformed part, you are welcome to have these engraved directly into the mould.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Cost of engraving\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The cost of engraving can vary considerably, depending on the type of engraving required. As a general rule, a recessed engraving is relatively inexpensive, whereas a raised engraving is considerably more labour-intensive and therefore more expensive.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Designing plastic parts: following the right guidelines for the best results\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>By following these basic design principles, potential sources of error can be avoided right from the design phase. This helps to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fleitfaden-zur-kostenreduktion-im-tiefziehen\">reduce costs\u003C\u002Fa>, minimises the need for iterative cycles and ensures safe production.\u003C\u002Fp>\u003Cp>Would you like to ensure that your component is optimally designed for deep drawing? We would be happy to assist you with the design and implementation of your deep-drawn parts, and we recommend consulting our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fdesign-guide\">Design Guide\u003C\u002Fa> for further guidance.\u003C\u002Fp>","design-guidelines-for-thermoformed-parts",{"id":606,"documentId":607,"createdAt":608,"updatedAt":609,"publishedAt":85,"locale":10,"title":610,"introduction":611,"content":612,"slug":613},374,"xyw31v2kgt544xwab2ikmfhi","2026-01-13T15:51:52.175Z","2026-05-27T12:45:54.495Z","Optimizing Intralogistics – How Trays Improve Your Intralogistics Processes","Rising customer demands, flexibility needs, and resource efficiency goals require companies to constantly improve intralogistics. To remain competitive and sustainable, they must optimize material flows, minimize handling times, and implement efficient storage and transport.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Optimizing intralogistics – Key facts at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Intralogistics organizes and controls all material and information flows within a company site in order to make processes more efficient and reduce costs.\u003C\u002Fli>\u003Cli>Thermoformed plastic trays support transport, handling, organization, and storage, helping to speed up workflows, reduce errors, and make optimal use of space.\u003C\u002Fli>\u003Cli>Trays are reusable, versatile, and sustainable, further increasing the efficiency and environmental friendliness of internal logistics.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request a tray for your intralogistics now\u003C\u002Fa>\u003C\u002Fp>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">→ Generate a 3D tray for your intralogistics now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Intralogistics?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Intralogistics refers to the organization of all material and information flows within a company’s premises. It includes warehouse movements, inventory control, and internal goods transport but excludes external logistics processes such as distribution and delivery.\u003C\u002Fp>\u003Cp>Intralogistics covers the planning, execution, and optimization of internal material handling to ensure seamless operations and cost efficiency.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FProzesse_am_Laptop_um_die_Intralogistik_zu_optimieren_72f7d889ab.png\" alt=\"Prozesse, um die Intralogistik zu optimieren\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Does Intralogistics Include?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Intralogistics includes all processes related to the flow of materials and information within a company. This covers the organization, control, and execution of internal goods movement as well as warehousing and inventory management.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Core Logistics Processes\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A key part of intralogistics is the picking and provision of goods. In addition, it includes material flow control and the continuous optimization of transport routes and storage capacities. Modern companies are increasingly using conveyor technology and warehouse automation to make processes more efficient.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Process Optimization Through Technology\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>To manage intralogistics reliably, digital systems are used. These include:\u003C\u002Fp>\u003Cul>\u003Cli>Warehouse management systems (WMS) for inventory control\u003C\u002Fli>\u003Cli>Material flow control systems for managing conveyor systems\u003C\u002Fli>\u003Cli>Automated systems for robotics and conveyor technology\u003C\u002Fli>\u003Cli>Data analytics and AI for optimizing inventory levels, routes, and throughput times\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">The Importance of Intralogistics for Internal Goods Flow\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The areas of intralogistics are therefore diverse and require continuous optimization. Plastic trays are used to support the internal transport of products and ensure optimal storage. In the next section, you will learn how thermoformed trays help optimize intralogistics.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Deep-Drawn Trays Optimize Your Intralogistics\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Intralogistics solutions are responsible for the planning, control, execution, and monitoring of all relevant processes. Through suitable measures, internal logistics aims to increase efficiency, ensure smooth coordination, and reduce costs in the long term. Thermoformed plastic trays are a key tool for achieving these goals.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSchwarzes_Tray_mit_durchsichtigem_Deckel_zur_Intralogistik_Optimierung_db1150db2d.png\" alt=\"Schwarzes Tray mit durchsichtigem Deckel zur Intralogistik Optimierung\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Improved Transport and Handling\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed plastic transport trays are used to optimize intralogistics and support the internal transport of products. The trays, also known as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-a-workpiece-carrier\">workpiece carriers, \u003C\u002Fa>are used within the production facility to transport semi-finished components, assemblies, or products from one workstation, machine, or system to the next. Each tray is specifically adapted to the conveyor technology and intralogistics processes.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ergonomic Handling Through Form-Fit Cavities and Grip Recesses\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Trays make machine-based or manual loading easier for your employees. They are equipped with form-fit cavities and grip recesses on the sides to ensure optimal transport within your industrial operations. Their lightweight design enables easy handling and reduces the need for additional transport resources.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:16.95%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTray_mit_Griffmulden_c26e3d62b5.jpg\" alt=\"Tray with recessed grips\">\u003Cfigcaption>Tray with recessed grips\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Efficient Organization\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:14.54%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTray_mit_Farbstreifen_a0b7ab35d4.png\" alt=\"Tray mit Farbstreifen\">\u003Cfigcaption>Tray with color stripes\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>Plastic trays enable structured organization and sorting of products. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftrays-with-color-stripes\">Color-coded trays \u003C\u002Fa>or labeled inserts enhance identification, reducing search times and errors in logistics operations.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Optimal Space Utilization\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:14.49%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStapeltrays_8482098e51.jpg\" alt=\"Stapelbare Trays für die Optimierung der Intralogistik\">\u003Cfigcaption>Stackable trays\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>Plastic trays are stackable, enabling space-saving and secure storage in the warehouse. Customized packing densities, meaning the number of items per tray packaging, also make inventory processes easier.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Maximum Packing Density\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The maximum packing density is usually determined by the requirements of your application, the technical limitations of thermoforming, and the capabilities of the system or robot in automated production lines.\u003C\u002Fp>\u003Cp>Based on these specifications, the available surface area is filled with form-fit cavities as efficiently as possible to achieve optimal utilization. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fhow-to-determine-tray-cavities\">This is how you determine the right cavities for your workpiece carrier.\u003C\u002Fa>\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sustainability and Reusability\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Reusable plastic trays offer a cost-effective and eco-friendly alternative to disposable packaging. Unlike single-use solutions, trays can be used multiple times, significantly reducing waste and lowering costs.\u003C\u002Fp>\u003Cp>Additionally, plastic trays are often fully recyclable, allowing them to be processed into \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-recyclate\">recycled materials\u003C\u002Fa> (regranulate) for further use.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:17.69%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTrays_als_Mehrwegverpackungen_d02b014c44.jpg\" alt=\"Trays als Mehrwegverpackungen\">\u003Cfigcaption>Trays as reuasable packaging\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Versatility and Customization\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The versatility of trays is another advantage in intralogistics. They are available in various sizes and designs and can be adapted to the specific requirements of different industries.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Application Areas of Plastic Trays\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fload-carriers-for-automotive\">Workpiece carriers for the automotive industry\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD trays\u003C\u002Fa> for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics \u003C\u002Fa>and semiconductor industries\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-production-automation\">Automation trays\u003C\u002Fa> for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Findustrial-solutions\">industrial applications\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Whether for transporting medical devices or storing food in the food industry, trays offer the flexibility needed to optimize intralogistics processes.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Optimizing Intralogistics with Trays – A Conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Plastic trays play a critical role in enhancing efficiency and sustainability in intralogistics. Their impact on safe and efficient storage and transport, along with their reusability, versatility, and organizational benefits, makes them an essential part of modern logistics operations.\u003C\u002Fp>","optimizing-intralogistics",{"id":615,"documentId":616,"createdAt":617,"updatedAt":618,"publishedAt":85,"locale":10,"title":619,"introduction":620,"content":621,"slug":622},356,"p46qiqgsab5462kx1xih63sn","2026-01-13T15:51:48.797Z","2026-06-02T16:18:28.203Z","SLC Inlays – The Optimal Solution for Transport and Storage","Small Load Carriers (SLCs) are widely used as transport and storage containers across various industries. Their functionality is enhanced by SLC Inlays, which protect delicate components, improve organization, and simplify handling. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">SLC inserts for transport and storage – Key facts at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>SLCs (small load carriers)\u003C\u002Fstrong> are standardised, stackable plastic containers designed for the safe transport and storage of small parts, and are compatible with automated systems.\u003C\u002Fli>\u003Cli>\u003Cstrong>SLC inserts\u003C\u002Fstrong> secure components, prevent damage, provide ESD protection and organise the interior for more efficient processes.\u003C\u002Fli>\u003Cli>SLC inserts are used \u003Cstrong>across a range of industries\u003C\u002Fstrong> (automotive, electronics, medical, food) and enhance protection, organisation and efficiency in storage and transport.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\">→ Request a SLC insert from our online shop now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are SLCs (Small Load Carriers)?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Small load carriers (SLCs) are standardised plastic containers used in logistics and manufacturing for the safe storage and transport of small parts. They are robust, stackable and compatible with automated storage systems. In short: SLC containers or other Euro boxes simplify every logistics process.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKLT_6e5f4d4777.png\" alt=\"SLC container in blue \">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Different types of SLC\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>R-\u003C\u002Fstrong>SLC\u003Cstrong> (Returnable Small Load Carrier)\u003C\u002Fstrong> – A sturdy container with a reinforced base, suitable for heavy loads and automated systems.\u003C\u002Fspan>\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>E-\u003C\u002Fstrong>SLC\u003Cstrong> (Ergonomic Small Load Carrier)\u003C\u002Fstrong> – Featuring special handles for easier manual handling.\u003C\u002Fspan>\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>RL-\u003C\u002Fstrong>SLC\u003Cstrong> (Returnable Lightweight SLC)\u003C\u002Fstrong> – A lighter version of the R-SLC for applications with lower load requirements.\u003C\u002Fspan>\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">SLC inserts: A secure and structured solution for small load carriers\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Euronorm containers are often already in use, but problems arise when components are transported in bulk and become damaged. To prevent this, suitable SLC inserts are required to ensure \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fcomponent-safety-for-small-parts\">component safety\u003C\u002Fa>.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\">online shop,\u003C\u002Fa> you can choose from 200 different SLC inserts designed to fit standard outer container sizes.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">What are SLC inserts?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>SLC inserts and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">Inlays\u003C\u002Fa> are custom-made container inserts, specially developed for SLCs and Euro-norm containers using the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">Plastic thermoforming process\u003C\u002Fa>. They ensure the organised, secure storage of components or parts that must not be handled as bulk goods. Container inserts can be used for any components, provided they fit into the recesses of the insert.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:501\u002F539;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKLT_Einlagen_im_Behaelter_b39a614efd.png\" alt=\"KLT Einlage im Behälter\" width=\"501\" height=\"539\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of SLC inserts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Container liners offer numerous advantages in transport and warehousing. These include:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Perfect protection for components\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Delicate components require special protection. Thanks to their precise fit, SLC inserts provide optimum support and prevent components from coming into contact with one another or being damaged by movement.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">More efficient processes\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The use of container inserts simplifies handling in production and logistics. SLC inserts divide the interior into compartments for different components. The clear organisation of components within the SLCs speeds up order picking and assembly, resulting in more efficient processes.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Protection against electrostatic discharge (ESD)\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>For electronic components, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\u002F3394252\">ESD-Inserts\u003C\u002Fa> can be used to protect them from electrostatic discharge. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD-Protection\u003C\u002Fa> is particularly essential in the electronics and automotive industries.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Efficient use of space\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The precise arrangement of the container inserts ensures that the available space in small load carriers and Euro containers is used to the full.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Typical applications for SLC inserts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:2500\u002F500;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStandard_ESD_Tiefzieheinlagen_aus_Kunststoff_frontal_012ce2ae90.png\" alt=\"Standard ESD-Tiefzieheinlagen aus Kunststoff_frontal\" width=\"2500\" height=\"500\">\u003C\u002Ffigure>\u003Cp>SLC inserts are used in many industries. They improve efficiency in warehousing and transport logistics, protect sensitive components and ensure hygienic storage.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">SLC inserts in the automotive sector\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive\u003C\u002Fa> sector, container inserts enable the safe storage and transport of bolts, nuts and other small parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">SLC inserts for the electronics industry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics industry\u003C\u002Fa> benefits from custom-made container inserts that protect sensitive components such as circuit boards and microchips from vibration.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Hygiene solutions for the medical technology sector\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medical field\u003C\u002Fa>, sterile SLC inserts ensure that instruments are stored hygienically and prevent contamination.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">SLC inserts in the food industry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">food industry\u003C\u002Fa> also relies on special, food-safe container liners that ensure safe and hygienic packaging.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview of the applications for SLC inlays\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Industry\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Applications for SLC inserts\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>automotive industry\u003C\u002Ftd>\u003Ctd>Organisation and protection for screws, nuts and small parts\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>electronics industry\u003C\u002Ftd>\u003Ctd>Safe transport of sensitive components (circuit boards, microchips)\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Medical technology\u003C\u002Ftd>\u003Ctd>Sterile storage of instruments and accessories\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>food industry\u003C\u002Ftd>\u003Ctd>Use of food-grade SLC inserts for hygiene and safety\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion – Increased efficiency thanks to SLC inserts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Whether in production, logistics or warehousing, SLC inserts significantly optimise the use of small load carriers and Euro-standard containers. They improve protection, organisation and the efficiency of work processes. Find the right small load carrier insert for your needs in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\">Online- shop\u003C\u002Fa>!\u003C\u002Fp>","slc-inlays-solution-for-transport-storage",{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631},366,"tkf2zbtub4pco4i5rxtd08gt","2026-01-13T15:51:50.667Z","2026-06-02T15:38:56.682Z","Construction Data in Thermoforming: These Factors Must Be Considered for Plastic Deep Drawn Parts","Deep drawn parts are custom-made and designed individually in a CAD format. Before a deep drawing tool is manufactured, a customer approval process of the CAD data or the derived, dimensioned PDF drawing takes place.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Design Data in Thermoforming - Key Points at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Precision of design data:\u003C\u002Fstrong> Dimensions, material, material thickness, draft angles, and radii must be carefully checked to ensure functionality, quality, and design of the thermoformed part.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cavity geometry & installation situation:\u003C\u002Fstrong> Components must be optimally designed for transport, assembly, and integration into the overall product. Tolerances and packing density are critical.\u003C\u002Fli>\u003Cli>\u003Cstrong>Process & data formats:\u003C\u002Fstrong> CAD data (STEP for 3D, PDF for 2D) is created, reviewed, approved, and sampled before series production starts (timeframe approx. 3–5 weeks).\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Do you already have a CAD file that you want to check for thermoformability? Upload it in our automated \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis\u003C\u002Fa> and receive a feasibility check within seconds.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Design Data?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>When referring to design data in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic thermoforming\u003C\u002Fa>, it means the CAD \u003Cstrong>(Computer-Aided Design)\u003C\u002Fstrong> file or the dimensioned drawing derived from it (often in PDF format) of the finished end product, in this case the thermoformed part.\u003Cbr>When creating the data, both customer requirements and Design for Manufacturing (DfM) recommendations from the thermoformer or toolmaker are incorporated.\u003C\u002Fp>\u003Ch3>Typical Parameters in Thermoforming\u003C\u002Fh3>\u003Cul>\u003Cli>Length dimensions\u003C\u002Fli>\u003Cli>Cavity geometries\u003C\u002Fli>\u003Cli>Material thicknesses\u003C\u002Fli>\u003Cli>Installation situations\u003C\u002Fli>\u003Cli>Cutouts for later processing\u003C\u002Fli>\u003Cli>Radii and draft angles for thermoformability\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">design of the plastic thermoformed part\u003C\u002Fa> serves as the basis for creating the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa> from aluminum. Once the tool is created, the next step is sample approval.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Customer Requirements for Design Data\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>formary usually develops the product and therefore the design data completely from scratch based on customer requirements. Sometimes, however, customers also provide finished CAD data for the thermoformed part. This happens either when the plastic thermoformed part already exists in the company and is being requested again, or when the internal design department has created a proposal.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Process with Existing CAD Data\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>Review for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-for-manufacturing-guide\">Design for Manufacturability (DfM)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Adjustment for thermoformability\u003C\u002Fli>\u003Cli>Customer review for completeness and accuracy\u003C\u002Fli>\u003C\u002Fol>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMaterialzusammensetzung_im_Konfigurator_englisch_534327f956.webp\" alt=\"Materialzusammensetzung_im_Konfigurator\">\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Format Should Your Construction Data Have?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>At formary, construction data is always provided to customers in the form of 2D drawings in PDF format and 3D data in STEP format.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What does STEP mean?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>STEP (\u003Cstrong>St\u003C\u002Fstrong>andard for the \u003Cstrong>E\u003C\u002Fstrong>xchange of \u003Cstrong>P\u003C\u002Fstrong>roduct model data) is a file type that enables the exchange of 3D models between CAD systems, regardless of which system the model was created on. \u003C\u002Fp>\u003Cp>The technical drawing includes detailed information about:\u003C\u002Fp>\u003Cul>\u003Cli>Textures\u003C\u002Fli>\u003Cli>Tolerances\u003C\u002Fli>\u003Cli>Material properties\u003C\u002Fli>\u003C\u002Ful>\u003Cp>A precise and careful review of the construction data is crucial to ensure that the thermoformed parts meet the desired requirements in terms of functionality, quality, and design.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Key Factors in Reviewing Construction Data for Approval\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>To ensure that the created deep draw design meets the requirements and guarantees functionality, the following factors must be carefully considered:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Dimensions\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The tolerance-compliant adherence to length dimensions (e.g., length x width x height) is always relevant to ensure that the final product meets the desired specifications. It should be checked whether the construction data were created with dimensional accuracy according to the agreed DIN ISO 2768 length measurement standard.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:56.52%;\">\u003Cimg style=\"aspect-ratio:768\u002F768;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefzieh_Abdeckung_Abmessungen_26cbd7985c_1_46c01ef13b.jpg\" alt=\"Abmaße des Tiefzieh-Werkzeugs\" width=\"768\" height=\"768\">\u003Cfigcaption>Part dimensions length x width x height\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Nesting Geometry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fhow-to-determine-tray-cavities\">Nesting geometry\u003C\u002Fa> is particularly crucial for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">plastic trays\u003C\u002Fa>. The following questions must be addressed:\u003C\u002Fp>\u003Cul>\u003Cli>Are the components placed in the agreed orientation?\u003C\u002Fli>\u003Cli>Are the components picked up by the desired geometry to ensure safe transport along the planned route (factory, road or rail)?\u003C\u002Fli>\u003Cli>Are handle recesses included for easy removal?\u003C\u002Fli>\u003Cli>Is the packing density as discussed?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The construction data should therefore provide clear information on the conditions and tolerances that apply to the nesting geometry of the plastic deep drawn parts. This means the parts should be designed to make optimal use of the available space while ensuring smooth production flow.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsm_0068_bit_003_formary_50028_transport_5a6906c90d_1_41d10960f4.jpg\" alt=\"Nestergeometrie des Tiefziehteils\">\u003Cfigcaption>Thermoformed tray with custom-fit cavities\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Assembly Situation\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">Covers\u003C\u002Fa> require specific data on the installation situation. The installation situation refers to the integration of the thermoformed part into the overall product or overall assembly of the customer's product. This is important to ensure that the part fits seamlessly into the intended environment and meets all assembly requirements. Therefore, it is necessary to check:\u003C\u002Fp>\u003Cul>\u003Cli>Do the dimensions at attachment and mounting points match the specifications?\u003C\u002Fli>\u003Cli>Are tolerances for assembly taken into account?\u003C\u002Fli>\u003Cli>Is compatibility with other components ensured?\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:61.04%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsm_0024_bit_003_formary_50200_abdeckung_084035d392_1_92852eb019.jpg\" alt=\"Verbausituation der Tiefziehteile\" width=\"640\" height=\"640\">\u003Cfigcaption>Thermoformed plastic covers\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Different plastics have different properties and are suitable for different applications. The material specified on the drawing should therefore be checked for accuracy.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Important Material Properties\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Temperature resistance\u003C\u002Fli>\u003Cli>Hardness\u003C\u002Fli>\u003Cli>UV protection\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Chemical resistance\u003C\u002Fli>\u003C\u002Ful>\u003Cp>More information on plastics can be found in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">Materials\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fmd_kunststoff_granulat_9b0e2d4096_1_267ca762c0.jfif\" alt=\"Material und Materialausgangsstärke\">\u003Cfigcaption>Plastic granules\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Initial Material Thickness\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The initial material thickness refers to the thickness of the plastic sheet or roll used in thermoforming. The initial material thickness was determined during quote creation based on technical criteria and can therefore be compared with it.\u003Cbr>If multiple initial thicknesses are sampled to achieve the optimal stability and geometry result, the final design drawing is updated accordingly to the chosen solution.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ To learn about the design rules to consider when designing thermoformed parts, read the article \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">Design Rules for Plastic Thermoformed Parts.\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Process Flow for Creating and Reviewing Construction Data at formary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>For the creation and review of design data, the process looks like this: \u003Cstrong>Requirements - Design - Data Approval - Sample - Sample Approval - Series.\u003C\u002Fstrong>\u003Cbr>In detail, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">project planning in thermoforming\u003C\u002Fa> proceeds roughly in the following steps:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Request Your Project\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Enter your requirements in the configurator and send your inquiry to formary. You will receive an offer within 24 hours.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1385\u002F570;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehteil_anfragen_Laptop_Mockup_2b60f6315d.png\" alt=\"Projektanfrage\" width=\"1385\" height=\"570\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Let Us Create Your Data\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In the second step, you have two options:\u003C\u002Fp>\u003Cul>\u003Cli>Do you have a design department?\u003Cul>\u003Cli>Then feel free to create your plastic thermoformed part yourself. You are welcome to consult our guide for the relevant aspects of thermoformable design. We will then review the drawing and adapt it for thermoformability.\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003Cli>Do you want to have your plastic thermoformed part designed from the start by designers with years of experience in all application areas?\u003Cul>\u003Cli>formary creates your data and designs optimal geometries for thermoforming according to your requirements.\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1079\u002F387;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDatenfreigabe_Laptop_Mockup_und_Konstruktion_8347a0859b.png\" alt=\"Datenerstellung\" width=\"1079\" height=\"387\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Receive Your Sample Quickly\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Depending on your timeline, you will receive samples from the appropriate option. There are 4 options available, depending on the purpose of the samples:\u003C\u002Fp>\u003Cul>\u003Cli>Samples from 3D printing tool\u003C\u002Fli>\u003Cli>Samples from Ureol tool\u003C\u002Fli>\u003Cli>Samples from partial segment series tool\u003C\u002Fli>\u003Cli>Samples from series tool\u003C\u002Fli>\u003C\u002Ful>\u003Cp>More information on the advantages, disadvantages, and applications of the different samples can be found under \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fprototyping\">Prototypes\u003C\u002Fa> and our blog article on \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Frapid-prototyping-in-thermoforming\">Rapid Prototyping\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1366\u002F445;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FWerkzeug_und_Bemusterung_cd0eff947f.png\" alt=\"Samplesanfrage\" width=\"1366\" height=\"445\">\u003C\u002Ffigure>\u003Cp> \u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. We Start Your Series Production\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>After successful sampling, we start series production. Depending on your material, the chosen tool design, the machine type for production, and the quantity, the lead time is approximately \u003Cstrong>3-5 weeks\u003C\u002Fstrong> from approval\u002Forder receipt to delivery of your series.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1504\u002F784;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSerienfertigung_ede6049265.png\" alt=\"Serienfertigung.png\" width=\"1504\" height=\"784\">\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion: Quality Assurance in Thermoforming Through Precise Review of Design Data\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Design data for the thermoformed part is therefore not only created for the manufacture of the tool but especially for the customer's review of the end product. At this stage, any additional or previously overlooked requirements can be easily identified and incorporated into the design. This ensures an efficient sampling and project process.\u003Cbr>formary ensures that a competent contact person is available to you throughout the entire project to clarify questions. Test it yourself now and request your plastic thermoformed part digitally. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">Configure now\u003C\u002Fa>.\u003C\u002Fp>","construction-data-in-thermoforming",{"id":633,"documentId":634,"createdAt":635,"updatedAt":636,"publishedAt":85,"locale":10,"title":637,"introduction":638,"content":639,"slug":640},336,"eozo3dmd50mtvypvxw59tzjd","2026-01-13T15:51:44.989Z","2026-06-02T15:34:33.901Z","Plastic Extrusion: How Plastic Film is Made","Plastic extrusion is a highly efficient manufacturing process that transforms plastic granules into continuous film. This versatile material is used across various industries, tailored to specific applications and performance requirements.","\u003Ch2>Plastic Extrusion - Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Plastic extrusion\u003C\u002Fstrong> is a forming process for manufacturing plastic products such as films and sheets.\u003C\u002Fli>\u003Cli>In the plastic extrusion process, \u003Cstrong>granules\u003C\u002Fstrong> or \u003Cstrong>powder\u003C\u002Fstrong> are melted in an extruder and pressed through a die into the desired shape.\u003C\u002Fli>\u003Cli>After cooling and smoothing, the semi-finished products (films, sheets) can be \u003Cstrong>further processed\u003C\u002Fstrong>, for example into plastic thermoformed parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request plastic thermoformed part now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What is Plastic Extrusion?\u003C\u002Fh2>\u003Cp>\u003Cstrong>Extrusion definition:\u003C\u002Fstrong> Plastic extrusion is a forming process for manufacturing plastic films. Extruding with plastic is done by forming and melting plastic granules.\u003C\u002Fp>\u003Ch3>What are Plastic Granules?\u003C\u002Fh3>\u003Cp>Plastic granules, also referred to as plastic pellets or plastic flakes, are a common starting form of plastics. They are small, granular particles made from various types of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">thermoplastics\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1080\u002F704;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_e0e0065308.png\" alt=\"Kunststoffgranulat\" width=\"1080\" height=\"704\">\u003Cfigcaption>Plastic flakes: Thinner, flat pieces of plastic\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>These particles typically have a uniform size and shape, making them ideal for processing in industrial manufacturing processes. In plastic extrusion, the granules or powder are pressed through a forming die to obtain the desired shape.\u003C\u002Fp>\u003Ch3>What is an Extruder?\u003C\u002Fh3>\u003Cp>The extruder ensures that the molten plastic flows into an elongated, thin form, called melt strands. After cooling and hardening, the strand is cut into small particle grains - the finished granules - which are then collected and stored in bags, big bags, or containers.\u003C\u002Fp>\u003Cp>These granules are then processed either in injection molding machines or again in the extruder. For \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">plastic films\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">sheets\u003C\u002Fa>, the latter applies.\u003C\u002Fp>\u003Ch2>Which Materials are Suitable for Plastic Extrusion?\u003C\u002Fh2>\u003Cp>Manufacturers of plastic films or sheets first purchase the required granules. This depends on which plastic film is to be processed. For example, if PET film is being produced, PET granules are needed.\u003C\u002Fp>\u003Ch3>Virgin Material or Recyclate as Starting Material\u003C\u002Fh3>\u003Cp>In addition to granules made from virgin material, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-recyclate\">recyclate\u003C\u002Fa> can also be used for the production of plastic film. With recyclate films, plastic flakes are fed into the extruder. These come from recycling, such as shredded plastic bottles or production remnants like edge strips and scrap grids.\u003C\u002Fp>\u003Ch3>Difference Between Granules and Flakes\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Granules\u003C\u002Fstrong>: uniform grains with defined shape and size, specifically produced for extrusion.\u003C\u002Fli>\u003Cli>\u003Cstrong>Flakes\u003C\u002Fstrong>: irregular, thin plastic pieces created through the recycling of used products.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>By choosing between virgin material and recycled material, manufacturers can influence the quality, sustainability, and costs of the plastic film.\u003C\u002Fp>\u003Ch2>Which Plastics Can Be Extruded?\u003C\u002Fh2>\u003Cp>There are various types of plastics that can be used for plastic extrusion, such as\u003C\u002Fp>\u003Cul>\u003Cli>Polyethylene (PE)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">Polypropylene (PP)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">Polyethylene terephthalate (PET)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">Polystyrene (PS)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">Polycarbonate (PC)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">Acrylonitrile butadiene styrene copolymer (ABS)\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>or also \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-are-bioplastics\">bioplastics\u003C\u002Fa>.\u003C\u002Fp>\u003Ch3>Selecting the Right Plastic\u003C\u002Fh3>\u003Cp>The choice of the right plastic depends on the desired properties of the plastic film, such as transparency, flexibility or rigidity, or resistance to external influences such as heat or cold resistance, UV resistance, etc.\u003C\u002Fp>\u003Ch2>Plastic Extrusion: How Does Film Production Work?\u003C\u002Fh2>\u003Cp>In extrusion technology with plastic and the associated film production, thermoplastics are transformed from granules into semi-finished products as films or thicker sheets. Semi-finished products describe products made from raw materials in their simplest form. In the following sections, plastic extrusion and how it works is explained in more detail.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1448\u002F1086;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPlattenduese_Werkstoff_Kunststoff_Extrusion_englisch_b99a6407e2.webp\" alt=\"Plattenduese_Werkstoff_Kunststoff_Extrusion\" width=\"1448\" height=\"1086\">\u003Cfigcaption>Plastic extrusion for the production of plastic film\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Feeding the Raw Material\u003C\u002Fh3>\u003Cul>\u003Cli>The raw material, in the form of granules or flakes, is fed into the plastic extruder via a hopper\u003C\u002Fli>\u003Cli>Depending on the desired properties of the plastic film, additives such as dyes, stabilizers, or additives (e.g. for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection\u003C\u002Fa> or flame retardancy) can be added\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Melting and Homogenizing the Plastic\u003C\u002Fh3>\u003Cul>\u003Cli>The granules are melted and homogenized in the electrically heated cylinder of the extruder.\u003C\u002Fli>\u003Cli>A screw inside the extruder ensures the conveyance of the melt flow and the mixing of the materials.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Extruder Design\u003C\u002Fh3>\u003Cul>\u003Cli>The design of the extruder varies depending on the material to be processed:\u003Cul>\u003Cli>\u003Cstrong>Horizontal dies\u003C\u002Fstrong> (with or without stagnation bars) are used for viscous melts\u003C\u002Fli>\u003Cli>\u003Cstrong>Vertical dies\u003C\u002Fstrong> are used for low-viscosity materials such as PET\u003C\u002Fli>\u003Cli>\u003Cstrong>Sheet systems\u003C\u002Fstrong> have a completely different design as well as different cooling sections\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Forming the Plastic Film\u003C\u002Fh3>\u003Cul>\u003Cli>The molten plastic leaves the extruder as a strand-shaped melt flow and is pressed into the slot die via a melt pump\u003C\u002Fli>\u003Cli>The slot die forms the melt flow into a thin layer, the preliminary stage of plastic film\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Smoothing and Finishing the Film\u003C\u002Fh3>\u003Cul>\u003Cli>The formed layer is guided over a smoothing unit with temperature-controlled rollers to ensure uniform material thickness\u003C\u002Fli>\u003Cli>The material web is then brought to the target width by single or multiple groove cutting\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>What Happens to the Plastic Film After Plastic Extrusion?\u003C\u002Fh2>\u003Cp>After the cooling section, in the cooled state, the plastic film is further processed. This process can include various steps:\u003C\u002Fp>\u003Ch3>Printing and Finishing\u003C\u002Fh3>\u003Cp>The film can be \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fprinting\">printed\u003C\u002Fa> with information, logos, or designs. Additionally, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\">surface treatments\u003C\u002Fa> such as lamination with other materials or the application of special coatings are possible to improve properties such as gloss, scratch resistance, or barrier effect.\u003C\u002Fp>\u003Ch3>Rolling or Cutting\u003C\u002Fh3>\u003Cp>Finally, the plastic film is usually wound onto rolls. For thicker plastic sheets, cutting is done with circular saws or guillotine shears to achieve the desired widths and lengths.\u003C\u002Fp>\u003Ch2>Plastic Film in Thermoforming\u003C\u002Fh2>\u003Cp>The resulting plastic rolls or plastic sheets are used after extrusion as starting material for the production of \u003Cstrong>plastic thermoformed parts\u003C\u002Fstrong>, among other things. For the production of plastic thermoformed parts in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic thermoforming\u003C\u002Fa>, semi-finished products are heated and drawn into a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa>. Here the semi-finished product is either unrolled from a plastic roll or placed in the machine in the form of a plastic sheet.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FIsometrische_Darstellung_eines_Tiefziehwerkzeugs_englisch_799db0f374.webp\" alt=\"Isometrische_Darstellung_Tiefziehwerkzeug\">\u003C\u002Fp>\u003Ch3>Initial Thickness of Plastic Films\u003C\u002Fh3>\u003Cp>The semi-finished product for plastic rolls has a \u003Cstrong>maximum initial thickness of 3mm\u003C\u002Fstrong>, although many manufacturers already set an upper limit at 2.5mm. This limit is solely due to the fact that plastic film can only be wound onto a roll to this thickness. After that, the semi-finished product becomes too inflexible for processing and is instead cut into sheets.\u003C\u002Fp>\u003Ch2>Application Possibilities of Plastic Film\u003C\u002Fh2>\u003Cp>Plastic film is a versatile material that is used in numerous industries after thermoforming. Whether as packaging, trays, or covers, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\">thermoformed products\u003C\u002Fa> made from plastic film combine protection, hygiene, and efficiency.\u003C\u002Fp>\u003Ch3>Industry Overview and Typical Applications of Plastic Thermoformed Parts\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">Automotive\u003C\u002Fa>: Thermoformed \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fload-carriers-for-automotive\">load carriers\u003C\u002Fa> and reusable trays for small parts, film thickness usually 0.2–0.8 mm.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">Medical technology\u003C\u002Fa>: Sterile \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Finlays-for-medical-products\">thermoformed trays\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-blister-packaging\">blisters\u003C\u002Fa>, and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">medical technology\u003C\u002Fa> housings protect instruments, devices, and sensitive electronics.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmechanical-engineering\">Mechanical engineering\u003C\u002Fa> & \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Findustrial-solutions\">industrial manufacturing\u003C\u002Fa>: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmachine-covers\">Machine covers\u003C\u002Fa>, containers for chemicals, and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fprotective-covers-for-cnc-parts\">protective covers\u003C\u002Fa>.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">Electronics\u003C\u002Fa>: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD trays\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">transport packaging\u003C\u002Fa> for semiconductors, circuits, or microchips.\u003C\u002Fli>\u003Cli>Consumer goods: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Finlay-packaging\">Inlay packaging\u003C\u002Fa> and blisters for retail and e-commerce.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-cosmetic-packaging\">Cosmetic articles\u003C\u002Fa>: Trays and inlays for storage and presentation of products.\u003C\u002Fli>\u003Cli>Food: Primary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">packaging\u003C\u002Fa> and trays for hygienic storage and freshness preservation.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Frobotics\">Robotics\u003C\u002Fa>: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-housing-for-robots\">Robot housings\u003C\u002Fa> for the assembly of robots.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Faerospace-defense\">Aerospace & defense\u003C\u002Fa>: Equipment trays, equipment housings for defense applications.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fagriculture-horticulture\">Agriculture & horticulture\u003C\u002Fa>: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-plant-containers\">Planting trays\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftractor-covers\">tractor covers\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplant-trays-made-of-plastic\">plant trays\u003C\u002Fa> for agricultural and garden technology.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>Plastic Extrusion with the formary Supplier Network\u003C\u002Fh2>\u003Cp>In most cases, plastic thermoformers purchase the required plastic film. However, there are also some \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fbecome-a-supplier\">suppliers\u003C\u002Fa> in the formary network that extrude their thermoforming film themselves. This in-house extrusion offers several advantages:\u003C\u002Fp>\u003Cul>\u003Cli>Customized solutions that are flexibly tailored to customer needs (material properties, additives, colors)\u003C\u002Fli>\u003Cli>Better control over the quality of the end product, because the film has exactly the desired properties\u003C\u002Fli>\u003Cli>Optimization of production processes and increased efficiency through deeper value creation\u003C\u002Fli>\u003C\u002Ful>\u003Cblockquote>\u003Cp>ℹ️ To learn about the other advantages our supplier network offers, watch the webinar on the procurement process for plastic thermoformed parts.\u003C\u002Fp>\u003C\u002Fblockquote>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=CZboBENMNjI\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Conclusion: Plastic Extrusion as Essential Foundation for the Thermoforming Process\u003C\u002Fh2>\u003Cp>Plastic extrusion is an essential process for the production of plastic films. Thanks to their diverse properties and application areas, thermoformed parts made from plastic films are indispensable in numerous industries. Do you need thermoforming films for your industry to benefit from the properties mentioned above? Then configure your thermoformed product now.\u003C\u002Fp>","plastic-extrusion",{"id":642,"documentId":643,"createdAt":644,"updatedAt":645,"publishedAt":85,"locale":10,"title":646,"introduction":647,"content":648,"slug":649},368,"u2oehuqlrx0hg9j751fu67kg","2026-01-13T15:51:51.054Z","2026-06-02T17:50:42.105Z","Thermoformed Plastic Parts in Use – Detailed Applications","Thermoformed plastic parts play a crucial role in almost every industry, from manufacturing and mechanical engineering to medicine and food production. In this article, we take a closer look at the various applications of thermoformed plastic parts across different industries.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Applications of thermoformed parts – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Thermoformed parts \u003C\u002Fstrong>are produced by deep-drawing plastic sheets and enable the cost-effective manufacture of customised moulds for many industries.\u003C\u002Fli>\u003Cli>\u003Cstrong>Material properties \u003C\u002Fstrong>such as ESD protection, food safety or UV resistance make thermoformed components suitable for a wide range of applications, e.g. in the medical, electronics or packaging sectors.\u003C\u002Fli>\u003Cli>The \u003Cstrong>applications \u003C\u002Fstrong>range from transport trays and enclosures to protective covers, inserts and trays in the industrial, logistics and consumer goods sectors.\u003C\u002Fli>\u003Cli>As an \u003Cstrong>experienced digital manufacturer\u003C\u002Fstrong> of thermoformed parts, formary supports you every step of the way, from design through to series production.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Enquire about thermoformed parts now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are Thermoformed Plastic Parts?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed parts, also known as deep-drawn plastic parts, are three-dimensional products produced by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic deep drawing\u003C\u002Fa> (plastic thermoforming). In plastic deep drawing, a semi-finished product is heated and drawn into a deep-drawing die using \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">vacuum\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpneumatic-forming\">pressure\u003C\u002Fa>. This results in bespoke products for packaging, logistics, mechanical engineering or medical technology.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:3325\u002F1494;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehen_von_der_Folie_f74265ad57.webp\" alt=\"Tiefziehen von der Folie\" width=\"3325\" height=\"1494\">\u003C\u002Ffigure>\u003Cp>Typical characteristics of deep-drawn components:\u003C\u002Fp>\u003Cul>\u003Cli>Large component dimensions are possible\u003C\u002Fli>\u003Cli>low \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">tool costs\u003C\u002Fa>\u003C\u002Fli>\u003Cli>short project durations\u003C\u002Fli>\u003Cli>cost-effective for small to medium-sized production runs\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Technical thermoformed parts are primarily used when components need to meet functional requirements such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection,\u003C\u002Fa> UV resistance or high dimensional stability.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Properties of Thermoformed Plastic Parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed plastic components are highly versatile, as they can be adapted to specific industries through different material configurations. Depending on the material, thermoformed components offer specific properties that are crucial in sectors such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medical\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics\u003C\u002Fa> :\u003C\u002Fp>\u003Cul>\u003Cli>ESD protection for sensitive electronic components\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fcleanroom-manufacturing-of-themoformed-parts\">Cleanroom hygiene\u003C\u002Fa> and sterility for medical technology and the pharmaceutical industry\u003C\u002Fli>\u003Cli>Food safety for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">food packaging\u003C\u002Fa>\u003C\u002Fli>\u003Cli>High-quality appearance for retail and display packaging\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Popular materials for thermoformed plastic parts\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_in_Haenden_873bd6b3b2.webp\" alt=\"Kunststoffgranulat in den Händen\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>There are numerous options when it comes to choosing the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">material\u003C\u002Fa>. The following are particularly commonly used:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpvc-plastic\">\u003Cstrong>PVC\u003C\u002Fstrong>\u003C\u002Fa>: Durable and versatile\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">\u003Cstrong>PET-A\u003C\u002Fstrong>\u003C\u002Fa>: Transparent and cost-effective\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">\u003Cstrong>ABS\u003C\u002Fstrong>\u003C\u002Fa>: Strong mechanical and thermal properties\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fmaterialien\u002Fps\">\u003Cstrong>PS\u003C\u002Fstrong>\u003C\u002Fa>: A standard reference plastic for thermoforming\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fmaterialien\u002Fpp\">\u003Cstrong>PP (Polypropylene)\u003C\u002Fstrong>\u003C\u002Fa>: Chemical resistance and lightweight\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Plastic thermoformed parts therefore meet both functional and aesthetic requirements. If you’d like to know how plastic differs from metal, read our article \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastics-vs-metal\">\u003Cu>Plastic vs. Metal: A Comparison\u003C\u002Fu>\u003C\u002Fa>.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Applications for thermoformed plastic parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed parts are used in a wide range of industries. We have divided the main applications into five categories.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transport and storage\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed parts for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">transport and storage\u003C\u002Fa> are used across all sectors of industry. Typical applications include:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-a-workpiece-carrier\">workpiece carrier\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fload-carriers-for-automotive\">load carrier\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD-Trays\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Stackable trays\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftray-packaging-for-metal-parts\">Tray packaging for metal parts\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftrays-with-color-stripes\">Trays with colour strips\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fonline-shop\">Inserts for SLC containers\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:22.91%;\">\u003Cimg style=\"aspect-ratio:572\u002F435;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefgezogenes_Transport_Tray_in_weiss_5400cae21f.jpg\" alt=\"Transport Tray in weiß\" width=\"572\" height=\"435\">\u003Cfigcaption>Transport Tray in white\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Are you planning a transport tray? Use the 3D data of your component to create an initial tray design with our  \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\"> 3D Tray Generator.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automation and Production\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-production-automation\">Automation trays\u003C\u002Fa> are used in production lines. They feature precisely fitted \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fhow-to-determine-tray-cavities\">mould cavities\u003C\u002Fa> and optimised \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fstacking-methods-for-trays\">stacking methods\u003C\u002Fa>, enabling robots to automatically grip and handle the components. A tray can pass through various production stages, which makes processes more efficient.\u003C\u002Fp>\u003Cp>When using thermoformed parts for automation and production, you therefore benefit from:\u003C\u002Fp>\u003Cul>\u003Cli>high-precision positioning\u003C\u002Fli>\u003Cli>Stackability\u003C\u002Fli>\u003Cli>Process integration\u003C\u002Fli>\u003Cli>low damage rate\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Thermoformed deep-drawn trays are therefore particularly suitable for production lines handling a variety of product variants. Read more in our article → \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fautomation-of-production-with-trays\">Automating production with plastic trays.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:22.26%;\">\u003Cimg style=\"aspect-ratio:1872\u002F1401;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSchwarzes_Automatisierungstray_e74ad9a10d.jpg\" alt=\"Schwarzes Automatisierungstray\" width=\"1872\" height=\"1401\">\u003Cfigcaption>Automation tray in black\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Inlays & Inserts\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">Plastic inserts and liners\u003C\u002Fa> are used in storage systems such as cases, drawers and packaging. Their purpose is to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fcomponent-safety-for-small-parts\">securely store components.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:21.49%;\">\u003Cimg style=\"aspect-ratio:613\u002F461;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FInlay_in_schwarz_4638810121.jpg\" alt=\"Inlay in schwarz\" width=\"613\" height=\"461\">\u003Cfigcaption>Inlay in black\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>In addition to the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fcomponent-safety-for-small-parts\">safety of small components\u003C\u002Fa>, deep-drawn inserts are also used as\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Finlay-packaging\">Inlays for packaging\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fdrawer-inserts\">Plastic drawer inserts\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Suitcase liners\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fthermoformed-plastic-packaging\">Thermoformed packaging\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Presentation packaging\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-blister-packaging\">Medical blister packs\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-cosmetic-packaging\">Cosmetics packaging\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>are used. Plastic inlays are generally scratch-resistant and resistant to cleaning agents. Thermoformed inlays can be visually adapted to your corporate identity guidelines to present a high-quality product with the desired distinguishing features.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Covers & Housings\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed parts in the form of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">\u003Cu>plastic covers\u003C\u002Fu>\u003C\u002Fa> protect sensitive equipment, machinery or other key components. They keep out dust, moisture and mechanical stress whilst ensuring a clean appearance.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:29.66%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffabdeckung_transparent_951230831a.jpg\" alt=\"Transparente Kunststoffabdeckung\" width=\"640\" height=\"640\">\u003Cfigcaption>Transparent plastic cover\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typical applications for covers and enclosures\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">Medical technology enclosures\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fprotective-covers-for-cnc-parts\">Protective covers for CNC parts\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmachine-covers\">Machine covers\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fcaravan-covers\">Caravan cladding\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftractor-covers\">Tractor body panels\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-batterie-housing\">Battery compartment\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">Plastic electronics enclosures\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Do you already have a CAD file for your thermoformed cover? With our  \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">Thermoforming Check\u003C\u002Fa>, you can check within 60 seconds whether your data is suitable for thermoforming.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Examples of Cover & Housing Applications\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Outdoor Applications\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Indoor Applications\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Exterior casings\u003C\u002Ftd>\u003Ctd>Covers for electronic devices\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Wheel arches & construction machinery covers\u003C\u002Ftd>\u003Ctd>Motor covers\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cable ducts & covers\u003C\u002Ftd>\u003Ctd>Distribution housings\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Enclosures for switch cabinets\u003C\u002Ftd>\u003Ctd>Protective housings for instruments\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Climate control system enclosures\u003C\u002Ftd>\u003Ctd>Security & alarm system casings\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Containers & Trays\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">Thermoformed containers\u003C\u002Fa> made of plastic are used in many industries as\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-plant-containers\">Planters\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Paint trays\u003C\u002Fli>\u003Cli>Moulds for casting\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-esd-containers\">ESD container\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Finlays-for-medical-products\">Thermoformed trays\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The key factors here are dimensional stability, recessed grips and a precise fit, which enable the safe handling of the components to be transported and stored.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:21.21%;\">\u003Cimg style=\"aspect-ratio:584\u002F460;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSchwarzer_Kunststoffbehaelter_2221391c07.jpg\" alt=\"Schwarzer Kunststoffbehälter\" width=\"584\" height=\"460\">\u003Cfigcaption>Black plastic container\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Material requirements for thermoformed parts in the form of deep-drawn containers\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>ABS and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fasa-plastic\">ASA\u003C\u002Fa> are the materials most commonly used for thermoformed containers intended for outdoor use, as these materials are UV-resistant. \u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion – Thermoformed Plastic Parts Offer Endless Possibilities\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoformed parts offer a flexible and cost-effective solution for a wide range of industrial applications. Whether transport trays, machine casings, housings or containers, thermoformed plastic parts provide functional, lightweight and cost-effective components.\u003C\u002Fp>\u003Cp>As an experienced digital manufacturer of thermoformed parts, formary supports you every step of the way, from design through to series production.\u003C\u002Fp>","applications-of-thermoformed-parts",{"id":651,"documentId":652,"createdAt":653,"updatedAt":654,"publishedAt":85,"locale":10,"title":655,"introduction":656,"content":657,"slug":658},341,"ijlrusckxsm6mygyyu1hkehr","2026-01-13T15:51:45.925Z","2026-06-02T15:32:06.930Z","Printing on Plastic Parts – The Difference Between Pad Printing and Screen Printing","Printing on thermoformed plastic parts enables detailed lettering, designs, and branding elements. Pad and screen printing are the most commonly used methods, depending on the application. This article explores these techniques in more detail.\n","\u003Ch2>\u003Cspan style=\"color:#005250;\">Screen printing vs. pad printing – the key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Plastic parts can be printed as part of the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fsurface-finishing-for-medical-housings\">surface finishing process\u003C\u002Fa> using screen printing (for flat surfaces) or pad printing (for uneven surfaces).\u003C\u002Fli>\u003Cli>\u003Cstrong>Screen printing \u003C\u002Fstrong>offers high colour intensity and is ideal for large print runs, whilst \u003Cstrong>pad printing \u003C\u002Fstrong>allows for finer details on complex surfaces.\u003C\u002Fli>\u003Cli>The \u003Cstrong>choice of printing method\u003C\u002Fstrong> depends on the shape of the part, the print size and the desired level of detail.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Select the appropriate printing method in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">In what situations are plastic parts printed? \u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoff_Tiefziehteile_bedrucken_95fd9d10d9.png\" alt=\"CMYK Kunststoffteil Mockup\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fprinting\">Printing on plastic parts\u003C\u002Fa> is a form of ‘off-mould decoration’ and is carried out after the moulding process. This is particularly common for products such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">covers,\u003C\u002Fa>  \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">trays\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">housings\u003C\u002Fa> produced by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic thermoforming\u003C\u002Fa> , printing on \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> is an ideal solution for customising the appearance of thermoformed parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What printing options are available?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Printing allows for the \u003Cstrong>customisation of thermoformed parts\u003C\u002Fstrong> and enhances their visual appeal. Logos, scales or control elements can be integrated directly, giving the thermoformed part a professional, brand-specific appearance.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Choosing the right printing method: Requirements for the print\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The print must be durable and scratch-resistant to ensure that the surfaces remain long-lasting even with heavy use. Choosing the right printing process is therefore important to ensure high quality, durability and a striking visual impact.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Plastics Can Be Printed?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>You can print on:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS plastic\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC plastic\u003C\u002Fa>\u003C\u002Fli>\u003Cli>PE plastic\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP plastic\u003C\u002Fa>\u003C\u002Fli>\u003Cli>and more.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>We will advise you on which plastic is best suited to your application, based on your requirements.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ Want to know what to look out for when choosing the right plastic? Then read our white paper \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\">Material Guide for Plastic Thermoformed Parts.\u003C\u002Fa> \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Printability and surface tension\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Printing on plastic parts is therefore possible with many thermoplastics; however, it is important to note that not all plastics are equally suitable for printing. Some plastics have a naturally low surface tension, which can make it difficult for the ink to adhere.\u003C\u002Fp>\u003Cp>In such cases, it is advisable to carry out specific pre-treatment processes, such as cleaning, degreasing or the use of bonding agents, in order to improve the adhesion of the paints.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">A comparison of printing methods: screen printing and pad printing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Two of the most common methods used for printing on plastic parts are screen printing and pad printing. Both printing processes have specific characteristics and are suitable for different applications. The following sections will help you decide whether screen printing or pad printing is the better choice for you.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Screen printing on plastic – ideal for flat surfaces\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Screen printing on plastic is particularly effective on flat surfaces and is frequently used on larger areas such as covers and casings, as the slightly coarse fabric texture limits the ability to reproduce very fine or small screen-printed designs with precision.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:453\u002F328;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSiebdruck_Verfahren_Grafik_c1136bba6f.png\" alt=\"Siebdruck Verfahren_Grafik\" width=\"453\" height=\"328\">\u003Cfigcaption>Screen printing process\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is screen printing?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Screen printing is a type of transfer printing and is based on a stencil principle that allows designs to be transferred very precisely onto a variety of surfaces. The screen printing process is also known as stencil printing because certain areas of the screen are covered by a stencil, so that the ink only passes through the open areas of the mesh onto the material.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">How does screen printing work?\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>\u003Cstrong>Preparing the screen:\u003C\u002Fstrong> A screen made of a fine-mesh fabric (usually polyester or polyamide) is stretched over a screen printing frame. A photosensitive coating is applied to this screen, which, after exposure, reproduces the desired screen-printed design.\u003C\u002Fli>\u003Cli>\u003Cstrong>Creating the stencil:\u003C\u002Fstrong> The design to be printed is transferred onto the screen by exposing the photosensitive layer using an exposure unit. Areas that are not exposed remain permeable to the ink, whilst the exposed areas block the ink.\u003C\u002Fli>\u003Cli>\u003Cstrong>Printing process:\u003C\u002Fstrong> In screen printing, the screen is placed on top of the plastic to be printed. A squeegee (a rubber blade) is used to pull the ink across the screen. The ink is forced through the open areas of the screen onto the material, creating the design.\u003C\u002Fli>\u003Cli>\u003Cstrong>Drying:\u003C\u002Fstrong> After printing, the printed material is dried to set the ink. This can be done by air-drying or in special drying units.\u003C\u002Fli>\u003C\u002Fol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1280\u002F720;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDrucken_eines_Siebdruck_Motivs_1661271939.png\" alt=\"Drucken eines Siebdruck Motivs\" width=\"1280\" height=\"720\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of screen printing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Here is a list of the main advantages and disadvantages of screen printing:\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Screen Printing Advantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Screen Printing Disadvantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>High color intensity:\u003C\u002Fstrong> Vibrant colors on dark materials.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Complex preparation:\u003C\u002Fstrong> Time-consuming and costly.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Durability:\u003C\u002Fstrong> Resistant to abrasion and weather conditions.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Limited detail accuracy:\u003C\u002Fstrong> Fine details can be difficult to reproduce.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Special colors & effects:\u003C\u002Fstrong> Metallic, fluorescent inks possible.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Time-consuming multi-color printing:\u003C\u002Fstrong> Each color requires a separate pass.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>High reproducibility:\u003C\u002Fstrong> Ideal for large print runs.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Limited flexibility:\u003C\u002Fstrong> Expensive design changes.\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Pad Printing on Plastic – Ideal for Uneven and Complex Surfaces\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Pad printing is a versatile and highly flexible printing process that is particularly well suited to printing on uneven and complex surfaces.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is pad printing?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Pad printing is an indirect printing process in which a flexible pad is used as a transfer element to apply ink to the desired material.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:17.42%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTampondruck_Grafik_b757f891a5.png\" alt=\"Tampondruck_Grafik\">\u003Cfigcaption>Pad Printing\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Does Pad Printing Work?\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>\u003Cstrong>Ink Transfer:\u003C\u002Fstrong> Ink is applied to an \u003Cstrong>engraved printing plate (cliché).\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>\u003Cstrong>Ink Pickup:\u003C\u002Fstrong> A silicone \u003Cstrong>pad\u003C\u002Fstrong> picks up the ink from the engraving.\u003C\u002Fli>\u003Cli>\u003Cstrong>Printing Process:\u003C\u002Fstrong> The pad presses the ink onto the plastic part.\u003C\u002Fli>\u003Cli>\u003Cstrong>Adaptation to Shape:\u003C\u002Fstrong> The flexible pad conforms to curved, concave, or convex surfaces.\u003C\u002Fli>\u003C\u002Fol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTampondruck_Verfahren_20dd277708.png\" alt=\"Tampondruck Verfahren\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and Disadvantages of Pad Printing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Pad Printing Advantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Pad Printing Disadvantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Flexible for complex shapes:\u003C\u002Fstrong> Suitable for curved and irregular objects.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Limited print size:\u003C\u002Fstrong> More suitable for smaller areas.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Fine lines and detailed motifs:\u003C\u002Fstrong> Precise reproduction of small and intricate designs.\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Thinner ink layer:\u003C\u002Fstrong> Less intense color compared to screen printing.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>High durability:\u003C\u002Fstrong> Resistant to abrasion, chemicals, and external influences.\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Efficiency:\u003C\u002Fstrong> Multi-color prints possible in one step.\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Quick drying:\u003C\u002Fstrong> Inks dry quickly at room temperature.\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Pad Printing vs. Screen Printing – Applications at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>If you want to print on plastic parts, the main difference between pad printing and screen printing lies in their respective applications and the types of surfaces that can be printed on.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Pad printing for irregularly shaped and complex parts\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Thermoformed plastic parts for \u003C\u002Fstrong>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">\u003Cstrong>the automotive industry:\u003C\u002Fstrong>\u003C\u002Fa> switches, buttons and controls in the vehicle interior, such as controls for air conditioning systems or radio buttons. Such parts often have curved or uneven surfaces, which can be printed on with precision using pad printing.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoformed plastic parts for \u003C\u002Fstrong>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">\u003Cstrong>the medical sector:\u003C\u002Fstrong>\u003C\u002Fa> Pad printing is used on \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">medical device housings\u003C\u002Fa> that are small and have complex shapes, such as the casings of inhalers and dialysis machines.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoformed plastic parts for \u003C\u002Fstrong>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">\u003Cstrong>electronics:\u003C\u002Fstrong>\u003C\u002Fa> Pad printing makes it possible to print fine details such as text and symbols onto uneven surfaces. Applications for this include \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD workpiece carriers\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">ESD transport packaging.\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGehaeuse_fuer_Ueberwachungsgeraete_9cb49afb3a.webp\" alt=\"Produktbeispiele Plastic Printing\">\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Screen printing for flat and large surfaces\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">\u003Cstrong>Plastic enclosures for electronics:\u003C\u002Fstrong>\u003C\u002Fa> Large enclosure components, such as those used in household appliances, computers or consumer electronics.\u003C\u002Fli>\u003Cli>\u003Cstrong>Large-format cladding:\u003C\u002Fstrong> Components used in sectors such as the automotive industry, including \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fcaravan-covers\">caravan covers\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftractor-covers\">tractor covers\u003C\u002Fa>.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTampondruck_auf_Kunststoff_Tiefziehteilen_Eng_bb533c2db4.webp\" alt=\"Tampondruck auf Kunststoff Tiefziehteilen Eng\">\u003C\u002Fp>\u003Cp>The choice between pad printing and screen printing therefore depends on the shape of the thermoformed part, the desired print quality and the intended use.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ Are you interested in further \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\">surface treatments\u003C\u002Fa> \n for plastic thermoformed parts? We also offer post-processing services such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fsanding-polishing\">sanding and polishing\u003C\u002Fa> as well as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fvarnishing\">painting\u003C\u002Fa>.\n    \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Pad Printing vs. Screen Printing - Comparison Table\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"table\" style=\"width:auto;\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Criterion\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Pad Printing\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Screen Printing\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Suitable Surfaces\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Uneven, curved, concave\u002Fconvex and complex shapes\u003C\u002Ftd>\u003Ctd>Flat, even and large surfaces\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Print Size\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Smaller print areas\u003C\u002Ftd>\u003Ctd>Large-format surfaces\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Detail Accuracy\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Very fine lines and intricate motifs possible\u003C\u002Ftd>\u003Ctd>Limited detail accuracy due to coarse textile structure\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Color Intensity\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Lower color intensity (thinner ink layer)\u003C\u002Ftd>\u003Ctd>High color intensity, even on dark materials\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Flexibility\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>High flexibility with complex shapes\u003C\u002Ftd>\u003Ctd>Limited flexibility for design changes\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Preparation\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Less elaborate\u003C\u002Ftd>\u003Ctd>Time and cost-intensive\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Multi-Color Printing\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Efficient - multiple colors in one step\u003C\u002Ftd>\u003Ctd>Time-consuming - each color requires separate pass\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Special Colors\u002FEffects\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Limited\u003C\u002Ftd>\u003Ctd>Metallic colors, fluorescent colors possible\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Drying\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Fast drying at room temperature\u003C\u002Ftd>\u003Ctd>Air drying or special drying facilities\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Durability\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Resistant to abrasion, chemicals\u003C\u002Ftd>\u003Ctd>Resistant to abrasion and weathering\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Reproducibility\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Good\u003C\u002Ftd>\u003Ctd>Very high reproducibility for large runs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Typical Applications\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>• Switches, buttons, control knobs (Automotive)\u003Cbr>• Medical device housings\u003Cbr>• ESD workpiece carriers\u003Cbr>• Small electronic parts\u003C\u002Ftd>\u003Ctd>• Large-format electronics housings\u003Cbr>• Caravan\u002Ftractor covers\u003Cbr>• Large-format panels\u003Cbr>• Household appliances\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Main Advantage\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Precise printing on complex 3D shapes\u003C\u002Ftd>\u003Ctd>Strong colors on large, flat surfaces\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Main Disadvantage\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Limited print size and color intensity\u003C\u002Ftd>\u003Ctd>Elaborate preparation, limited detail accuracy\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Printing on plastic parts using screen printing or pad printing – A summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cstrong>So which is better\u003C\u002Fstrong> – pad printing or screen printing? When comparing the two printing methods, pad printing stands out as the best option for printing on uneven and complex surfaces. This also makes it possible to print highly detailed designs, albeit in a smaller size and with lower colour intensity.\u003C\u002Fp>\u003Cp>Screen printing is particularly suitable for large, flat surfaces and produces very vibrant colours. However, it is significantly more labour-intensive than pad printing, and intricate designs are rather difficult to reproduce due to the coarse texture of the fabric. If you are \u003Cstrong>unsure\u003C\u002Fstrong> whether to choose pad printing or screen printing for your \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">project\u003C\u002Fa>, please \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact\u003C\u002Fa> us. We’ll be happy to help.\u003C\u002Fp>","printing-on-plastic-parts",{"id":660,"documentId":661,"createdAt":662,"updatedAt":663,"publishedAt":85,"locale":10,"title":664,"introduction":665,"content":666,"slug":667},335,"dgjboddl2fyoljil9zl9btkp","2026-01-13T15:51:44.762Z","2026-06-02T17:08:05.637Z","Plastic Containers in Industry – Common Mistakes and How to Avoid Them","Industrial plastic containers must withstand mechanical, chemical, and long-term stresses. They are designed to support your processes and employees.","\u003Ch2>Avoiding errors with plastic containers- The essentials in brief\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Ergonomic design\u003C\u002Fstrong> and stable grip recesses extend the service life of plastic trays and prevent health risks when lifting.\u003C\u002Fli>\u003Cli>\u003Cstrong>Reinforcements\u003C\u002Fstrong> such as ribs and special adaptations increase stability and prevent cracks, buckling, or wobbling of the trays.\u003C\u002Fli>\u003Cli>\u003Cstrong>Individual lids\u003C\u002Fstrong> protect the contents from contamination and meet important hygiene requirements in various industries.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request plastic container now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:24.82%;\">\u003Cimg style=\"aspect-ratio:768\u002F768;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefzieh_Behaeltnis_Griffmulden_4fa4175c3f.jpg\" alt=\"Griffmulden bei Kunststoffwannen\" width=\"768\" height=\"768\">\u003Cfigcaption>Grip recesses help with the ergonomic carrying of plastic containers\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>What does ergonomics have to do with plastic containers?\u003C\u002Fh2>\u003Cp>Ergonomics is a central criterion for plastic containers. The area of application and weight when filled are crucial, as well as whether machines transport them or employees lift them from KLTs and boxes.\u003C\u002Fp>\u003Ch3>Health risks from excessive weight\u003C\u002Fh3>\u003Cp>According to specialists in occupational medicine, the following one-time lifting loads can already be harmful to health:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Women:\u003C\u002Fstrong> from 25 kg\u003C\u002Fli>\u003Cli>\u003Cstrong>Men:\u003C\u002Fstrong> from 40 kg\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Therefore, we recommend filling plastic containers with a \u003Cstrong>maximum of 14 kg\u003C\u002Fstrong> or not exceeding a \u003Cstrong>maximum weight of 35 kg\u003C\u002Fstrong> when handled by two people.\u003C\u002Fp>\u003Ch3>Ergonomic design for safe handling\u003C\u002Fh3>\u003Cp>For safe and fatigue-free work, weight, haptics, and shape are crucial:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Carrying handles or grip recesses:\u003C\u002Fstrong> stable, well-positioned, and aligned with the center of gravity of the filled container.\u003C\u002Fli>\u003Cli>\u003Cstrong>Grip design:\u003C\u002Fstrong> the grip should be able to be fully enclosed with the hand, offer a comfortable grip feeling, and not wobble.\u003C\u002Fli>\u003Cli>\u003Cstrong>Stability:\u003C\u002Fstrong> an unstable or swinging container leads to a feeling of insecurity when carrying and increases the risk of injury.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Support through ergonomic aids\u003C\u002Fh3>\u003Cp>In addition to an optimal weight, employees can be supported by devices that simplify lifting, carrying, and setting down. These include lifting aids, grip recesses, or shape-adapted transport racks.\u003Cbr>In the next section, we show how critical points on plastic containers can be \u003Cstrong>specifically stabilized\u003C\u002Fstrong> to ensure maximum safety and longevity.\u003C\u002Fp>\u003Ch2>Avoiding buckling, cracks, and wobbling in plastic containers\u003C\u002Fh2>\u003Cp>Plastic containers that buckle or break open when lifted cause frustration at work. But where do kinks and cracks in plastic actually come from? Plastic damage usually occurs because:\u003C\u002Fp>\u003Cul>\u003Cli>the loading weight was not considered during \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">construction\u003C\u002Fa>\u003C\u002Fli>\u003Cli>the plastic cannot withstand pointed, sharp-edged loads OR\u003C\u002Fli>\u003Cli>the plastic container has been in use for too long.\u003C\u002Fli>\u003C\u002Ful>\u003Cblockquote>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> With our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis\u003C\u002Fa>, you can check the data of your plastic container for thermoformability and problem areas.\u003C\u002Fp>\u003C\u002Fblockquote>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDf_M_Analyse_Software_Mockup_5e3c27edb2.webp\" alt=\"DfM-Analyse Software Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch2>Can plastic containers be designed as reusable products?\u003C\u002Fh2>\u003Cp>Of course they can. Whenever possible, we try to design the plastic container as a reusable product, since longevity makes sense for economic and ecological reasons.\u003C\u002Fp>\u003Ch2>Decisive criteria for the longevity of plastic containers\u003C\u002Fh2>\u003Cul>\u003Cli>How long is the plastic container in use?\u003C\u002Fli>\u003Cli>What is it used for and what is being transported?\u003C\u002Fli>\u003Cli>How high are the load values in kilograms?\u003C\u002Fli>\u003Cli>Is it exposed to additional mechanical stress from the environment or from the contents?\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Targeted reinforcement of plastic containers\u003C\u002Fh3>\u003Cul>\u003Cli>Ribs, bracing, or transition contours\u003C\u002Fli>\u003Cli>stronger base materials\u003C\u002Fli>\u003Cli>optimized material distribution through adapted forming ratio\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Our experts select the appropriate material and the ideal wall thickness, always material-saving and application-oriented.\u003C\u002Fp>\u003Ch2>Special applications of plastic containers\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:22.74%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fbehaeltnis_fraesung_nesterboden_01_6a79675f1e.png\" alt=\"Individuelle Fräsungen der Kunststoffwanne\" width=\"1299\" height=\"1299\">\u003Cfigcaption>individual milling on the bottom of the container\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>The application of plastic containers is as diverse as the industry itself. From catch trays to rinse trays or plastic wash tubs to food-safe containers, everything can be found.\u003C\u002Fp>\u003Ch4>Design possibilities for plastic containers\u003C\u002Fh4>\u003Cul>\u003Cli>For special requirements, openings and apertures can be incorporated in the bottom.\u003C\u002Fli>\u003Cli>Connection systems to surrounding objects can be attached\u003C\u002Fli>\u003Cli>Tight tolerances? This can be taken into account in the thermoforming tool at the critical points\u003C\u002Fli>\u003Cli>Sensitive high-gloss containers can be delivered specially packaged with foil and intermediate layers to avoid scratches during transport and storage\u003C\u002Fli>\u003Cli>If you want to additionally protect the contents of the plastic container or prepare them for freight, then a suitable lid is a must.\u003C\u002Fli>\u003C\u002Ful>\u003Cblockquote>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fdesign-guide\">Design Guide\u003C\u002Fa>, you will find the most important criteria for the design of thermoformed plastic parts.\u003C\u002Fp>\u003C\u002Fblockquote>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1600\u002F797;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDesign_Guide_Banner_Mockup_Englisch_89a97af835.webp\" alt=\"Design Guide Banner Mockup English\" width=\"1600\" height=\"797\">\u003C\u002Ffigure>\u003Ch2>Plastic lids for plastic containers – precise fit, secure, and versatile\u003C\u002Fh2>\u003Cp>A plastic lid must above all do one thing: fit – both on the plastic container and to your specific application. It reliably seals the container and fulfills important functions in many industries:\u003C\u002Fp>\u003Ch3>Protection and hygiene\u003C\u002Fh3>\u003Cp>In the food industry and pharmaceutical industry, compliance with strict hygiene requirements is paramount. A suitable plastic lid reliably protects the contents from:\u003C\u002Fp>\u003Cul>\u003Cli>Dust\u003C\u002Fli>\u003Cli>Contamination\u003C\u002Fli>\u003Cli>Particles\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Furthermore, sterilizability, temperature resistance, and chemical resistance are mandatory in many areas of application, not only in the food and pharmaceutical sectors, but also in chemistry, medical technology, and in high-tech industries.\u003C\u002Fp>\u003Ch3>Other important functions\u003C\u002Fh3>\u003Cp>Plastic lids not only prevent the ingress of dirt, but also:\u003C\u002Fp>\u003Cul>\u003Cli>Leakage of liquids\u003C\u002Fli>\u003Cli>Falling out of sensitive components\u003C\u002Fli>\u003Cli>Damage during transport or storage\u003C\u002Fli>\u003C\u002Ful>\u003Cp>In addition, lids can serve as a plug-in and stacking system for storage and intermediate storage. Important: The contents should be completely recessed or flush with the edge of the plastic container at most to ensure a secure seal.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:5000\u002F3333;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FBatteriegehaeuse_aus_Kunststoff_0020aa3d93.webp\" alt=\"Batteriegehäuse aus Kunststoff\" width=\"5000\" height=\"3333\">\u003Cfigcaption>Example of a Plastic container with lid ©\u003Cspan style=\"background-color:white;color:black;font-family:Barlow, serif, EmojiFont;\">DG\u002FBebop Media\u003C\u002Fspan>\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Closure types for plastic lids\u003C\u002Fh3>\u003Cp>Depending on requirements, different closure techniques are used:\u003C\u002Fp>\u003Cul>\u003Cli>Slip-on closure: sits loosely on top, easily removable\u003C\u002Fli>\u003Cli>Snap closure: locking mechanism holds the lid securely on the container\u003C\u002Fli>\u003Cli>Hinged lid: firmly fixed to the container, for opening and closing\u003C\u002Fli>\u003C\u002Ful>\u003Cp>A transparent plastic lid additionally offers the advantage that you can check the contents at any time without opening the container.\u003C\u002Fp>\u003Chr>\u003Ch2>Conclusion - Avoiding common errors with plastic containers\u003C\u002Fh2>\u003Cp>To extend the service life of your plastic containers and avoid damage, you should pay attention to proper handling, use stable carrying handles, and keep an eye on the loading weight.\u003Cbr>Additionally, individual adaptations such as reinforced structures and special packaging can help increase stability and protect the contents. In summary, plastic containers are extremely durable and survive many production cycles with proper handling.\u003C\u002Fp>","plastic-retainers-common-mistakes",{"id":669,"documentId":670,"createdAt":671,"updatedAt":672,"publishedAt":85,"locale":10,"title":673,"introduction":674,"content":675,"slug":676},343,"ipuvt9l41d8xu1pvb1u40off","2026-01-13T15:51:46.283Z","2026-06-18T14:47:17.378Z","Supplier Guide for Plastic Thermoformed Parts – 10 Key Factors That Matter","Choosing the right supplier for plastic thermoformed parts is crucial for the quality, efficiency, and cost-effectiveness of your production. Our 10 tips will show you what to look for when selecting a supplier.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Supplier guide for plastic thermoformed parts – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>A reliable supplier for thermoformed plastic parts can be assessed using ten objective criteria: technology, material, industry experience, quality assurance, certifications, delivery reliability, post-processing, price-performance ratio, communication and IP protection.\u003C\u002Fli>\u003Cli>The 10-criteria evaluation model with pass and KO criteria makes supplier offers comparable, instead of relying on gut feeling alone.\u003C\u002Fli>\u003Cli>formary connects buyers with more than 100 pre-qualified thermoforming manufacturers in Germany. Matching is algorithmic and based on process, material, industry and certification requirements.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Download the full \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fsupplier-guide\">Supplier Guide\u003C\u002Fa> white paper now\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">When is a structured supplier evaluation worthwhile?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>A systematic evaluation is particularly valuable in three situations:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>New sourcing of a technical component\u003C\u002Fstrong> such as a housing, tray or cover. If tool investments amount to several thousand euros, the supplier decision often creates a multi-year commitment.\u003C\u002Fli>\u003Cli>\u003Cstrong>Supplier change or second sourcing\u003C\u002Fstrong> due to delivery bottlenecks, quality issues or price drift. In this case, a documented evaluation process also provides a solid basis for discussion with the existing supplier.\u003C\u002Fli>\u003Cli>\u003Cstrong>Tool transfer from a previous supplier.\u003C\u002Fstrong> Here, tool condition, process capability and initial sampling at the new production site need to be evaluated → See the article on tool transfer in thermoforming.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>In all three cases, one principle applies: anyone who compares only the unit price ignores 60–80% of the decision-relevant costs. Total-cost-of-ownership factors such as complaint rate, delivery reliability, communication effort and IP risk determine the actual economic viability.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">The 10-Criteria evaluation model at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The following table summarizes the full evaluation model. It is based on formary’s experience with B2B thermoforming projects in the DACH region.\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Criterion\u003C\u002Fth>\u003Cth>Pass criterion\u003C\u002Fth>\u003Cth>KO criterion\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Technological capabilities\u003C\u002Ftd>\u003Ctd>Suitable process, such as vacuum forming or pressure forming, and machine format, such as roll or sheet, are available\u003C\u002Ftd>\u003Ctd>Supplier calculates using machines that are not optimally or economically suited to the component, quality requirements or quantity\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Material availability & expertise\u003C\u002Ftd>\u003Ctd>Experience with your material and documented supply chain for semi-finished material\u003C\u002Ftd>\u003Ctd>Material is processed for the first time on a project-specific basis, without prior experience\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Experience & industry expertise\u003C\u002Ftd>\u003Ctd>At least three comparable reference projects in terms of process, quantity and industry\u003C\u002Ftd>\u003Ctd>No comparable reference, no industry experience\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Quality assurance (SPC, FAI \u002F EMPB)\u003C\u002Ftd>\u003Ctd>SPC process control for key processes, EMPB or FAI initial sampling\u003C\u002Ftd>\u003Ctd>No measurement-based process control, no documented initial sampling\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Certifications\u003C\u002Ftd>\u003Ctd>ISO 9001 as a baseline, industry-specific certifications such as IATF 16949, ISO 13485 or ISO 14001\u003C\u002Ftd>\u003Ctd>Required industry certification is missing, such as IATF 16949 for direct automotive supply\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Delivery reliability & capacity\u003C\u002Ftd>\u003Ctd>Documented on-time delivery rate, free machine capacity for your project\u003C\u002Ftd>\u003Ctd>No OTD KPI available, utilization > 95% without a scalability path\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Post-processing from a single source\u003C\u002Ftd>\u003Ctd>Milling \u002F punching, assembly and surface finishing internally or with one fixed subcontractor\u003C\u002Ftd>\u003Ctd>Several uncoordinated subcontractors with separate invoicing and no binding responsibility from one supplier\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Price-performance ratio\u003C\u002Ftd>\u003Ctd>Transparent tool and unit costs, comprehensible cost calculation\u003C\u002Ftd>\u003Ctd>Lump-sum offer without breakdown of tooling \u002F material \u002F labor hours\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Communication & project management\u003C\u002Ftd>\u003Ctd>German- or English-speaking contact person, response < 2 working days, clear project plan\u003C\u002Ftd>\u003Ctd>Communication breakdown, no assigned project lead, no status updates\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>IP protection, NDA & tool ownership\u003C\u002Ftd>\u003Ctd>Willingness to sign an NDA before data exchange, clear tool ownership clause\u003C\u002Ftd>\u003Ctd>No NDA, unclear tool ownership, data reuse permitted\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">10 key points to consider when looking for a supplier of plastic thermoformed parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>We’ve summarised the \u003Cstrong>10 most important criteria\u003C\u002Fstrong> for selecting a supplier of plastic thermoformed parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Technical skills\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTechnologische_Faehigkeiten_bei_Lieferanten_7fba251155.png\" alt=\"Technologische Fähigkeiten bei Lieferanten\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">Thermoforming \u003C\u002Fa>has many applications and end products. Pay attention to the following points:\u003C\u002Fp>\u003Cul>\u003Cli>Which thermoforming process is suitable: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">vacuum forming\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpneumatic-forming\">pressure forming?\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Which semi-finished material format do you need: roll-stock material or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">film production\u003C\u002Fa> up to 960 × 650 mm, or thick-gauge \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">sheet material\u003C\u002Fa> up to 4,000 × 3,000 mm and up to 15 mm material thickness?\u003C\u002Fli>\u003Cli>Does the supplier have the required tooling equipment, such as punching stations and CNC trimming, in-house?\u003C\u002Fli>\u003Cli>Are the achievable tolerances for your component sufficiently documented?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>The process and machine format are directly available at the supplier. Tooling and final inspection are handled by one party.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Production is carried out on a machine park that is not optimally suited, resulting in unnecessarily high costs or quality risks.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Machine list with format ranges and processes, sample parts with tolerance specifications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Availability of materials\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In plastics processing, first, selecting the right material and second, ensuring its availability are essential. Ask about:\u003C\u002Fp>\u003Cul>\u003Cli>Experience with standard \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">materials \u003C\u002Fa>such as HD-PE, PC, PET-G, PS, PVC, and with special materials such as flame-retardant, ESD, or medical-grade materials?\u003C\u002Fli>\u003Cli>What is the situation regarding inventory levels or a secured supply chain for semi-finished materials?\u003C\u002Fli>\u003Cli>In-house production, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastics extrusion,\u003C\u002Fa> to ensure price and delivery reliability?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>At least one documented reference part in the desired material, as well as verifiable supply of semi-finished material.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>The material is processed for the first time on a project-specific basis, without a structured sampling plan.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Material overview, material certificates, stock verification, or framework agreement with semi-finished material supplier.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Experience & expertise\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastics processing involves a wide range of material requirements, geometries, trimming and post-processing techniques, and quality requirements. Check the following:\u003C\u002Fp>\u003Cul>\u003Cli>Comparable reference projects: similar process, similar quantity, same industry.\u003C\u002Fli>\u003Cli>Are industry-specific requirements understood? Examples: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive \u003C\u002Fa>(PPAP, IMDS), \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medical & pharmaceutical\u003C\u002Fa> (ISO 13485, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fcleanroom-manufacturing-of-themoformed-parts\">cleanroom production\u003C\u002Fa>).\u003C\u002Fli>\u003Cli>Is \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-for-manufacturing-guide\">design-for-manufacturing\u003C\u002Fa> support offered? Does the supplier identify risks in CAD models early?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Similar references, with at least one technically similar reference. Industry-specific requirements are named independently.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>No comparable reference; industry requirements must be specified by purchasing.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Reference list, anonymized sample drawings, if applicable reference customer contact.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Quality Assurance\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1536\u002F1024;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FQualitaet_und_Sicherheit_im_Thermoforming_gewaehrleisten_6c7b4c4ea4.webp\" alt=\"Qualität und Sicherheit im Thermoforming\" width=\"1536\" height=\"1024\">\u003C\u002Ffigure>\u003Cp>If a supplier has a robust \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fquality-assurance\">quality assurance\u003C\u002Fa> system, this reduces complaints and relieves your own incoming goods inspection. Plastic parts require tool approval, also known as sample approval. Important points include:\u003C\u002Fp>\u003Cul>\u003Cli>ISO certifications, e.g. ISO 9001\u003C\u002Fli>\u003Cli>trained personnel\u003C\u002Fli>\u003Cli>precise measuring equipment\u003C\u002Fli>\u003Cli>fast sample approvals\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Certifications are provided, supplier audits are enabled.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>No measurement-based process control, no documented initial sampling.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Certifications\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Pay particular attention to the following certifications:\u003C\u002Fp>\u003Cul>\u003Cli>ISO 9001 as a basic requirement\u003C\u002Fli>\u003Cli>IATF 16949 for direct supply to the automotive industry, based on ISO 9001 and supplemented by automotive-specific requirements such as risk management and supply chain control\u003C\u002Fli>\u003Cli>ISO 13485 for medical technology\u003C\u002Fli>\u003Cli>Are certificates valid, including issue date, scope, and issuing body?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>ISO 9001 is in place, and the mandatory industry-specific certificate fits the application.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Mandatory industry certificate is missing.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Current certificates as PDFs, scope of certification, if applicable associated audit report.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">6. Delivery reliability & capacity\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Planning reliability is crucial when searching for reliable suppliers for thermoformed plastic parts. Check:\u003C\u002Fp>\u003Cul>\u003Cli>On-time delivery (OTD): percentage of deliveries made on time against the agreed date.\u003C\u002Fli>\u003Cli>Free machine capacity for your project within the required time frame, including a scaling path for demand peaks if needed.\u003C\u002Fli>\u003Cli>Forecast and call-off model: How are rolling forecasts processed? What are the lead times?\u003C\u002Fli>\u003Cli>Emergency concept: What happens in the event of machine failure, material shortages, or a wave of illness?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Documented OTD figure for the last 12 months, free capacity in the planned time frame verified.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>No OTD figure available, machine utilization > 95% without a recognizable scaling path.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>OTD evaluation for the last 12 months, capacity plan, escalation process.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">7. Post-processing from a single source\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FNachbearbeitungsverfahren_3296c30b37.png\" alt=\"Nachbearbeitungsverfahren als Kriterium für die Lieferantensuche\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>Several uncoordinated subcontractors increase organizational effort, delay deliveries, and create quality risks through additional transport. Important questions include:\u003C\u002Fp>\u003Cul>\u003Cli>Is cutting or trimming, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fseparating\u002Fcnc-milling\">milling \u003C\u002Fa>or punching, done internally or by a fixed partner?\u003C\u002Fli>\u003Cli>Are joining and assembly included, such as clipping, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fconnecting\u002Fbonding\">bonding,\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fconnecting\u002Fwelding\">welding?\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Are surface finishing processes offered, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fvarnishing\">painting,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fprinting\">printing,\u003C\u002Fa> or laminating?\u003C\u002Fli>\u003Cli>Is packaging and kitting handled?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>All required post-processing steps under one contract, with clear quality responsibility.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Several uncoordinated subcontractors with separate invoicing and no continuous quality responsibility.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Overview of post-processing methods, naming of partners, quality clauses in the subcontract.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">8. Price-performance ratio\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Prices for plastic parts vary significantly from supplier to supplier, and the reasons are often difficult for outsiders to understand. Reasons for price differences may include:\u003C\u002Fp>\u003Cul>\u003Cli>Breakdown of tooling costs, material costs, hourly rate, and post-processing; see also the background in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">unit costs and tooling costs in thermoforming.\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Cost drivers: machine fit, material availability, utilization, in-house vs. outsourced post-processing.\u003C\u002Fli>\u003Cli>Logistics costs, packaging costs, incoming inspection effort on your side.\u003C\u002Fli>\u003Cli>Total cost calculation over the tool life, not just the unit price.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Transparent offer with breakdown and comprehensible calculation basis.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Lump-sum offer without breakdown of tooling \u002F material \u002F hours \u002F post-processing.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Detailed offer breakdown, if applicable calculation scheme.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">9. Communication & project management\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FEin_Mann_der_ein_Dokument_abstempelt_0e862d452f.png\" alt=\"Qualitätssicherung bei der Lieferantensuche\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>Thermoformed plastic parts are usually new developments with the thermoformer or their toolmaker, based on your product requirements. As someone who is not a thermoforming expert, you want to be comprehensively informed, professionally advised, and made aware of potential risks and how to prevent them. Communication is an often underestimated criterion that directly affects delivery reliability in crisis situations.\u003C\u002Fp>\u003Cp>\u003Cstrong>What you should check:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Language: Is a contact person available in German or English?\u003C\u002Fli>\u003Cli>Response time to inquiries, target: under 2 working days for RFQ follow-up questions, under 24 hours for escalations.\u003C\u002Fli>\u003Cli>Fixed project management with a named deputy?\u003C\u002Fli>\u003Cli>Standardized status updates, weekly, monthly, or according to project milestones?\u003C\u002Fli>\u003Cli>Data exchange via a secure channel, not sending design data as unencrypted email attachments?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Named project manager, clearly defined communication rhythm, secure data channels.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Communication breakdown in the RFQ process, no assigned project manager, no structured status updates.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Project organization chart, sample status report, communication plan.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">10. IP protection, NDA & tool ownership\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastic thermoforming requires an investment in thermoforming tools that are designed for the supplier’s machine park. When choosing a supplier, a long-term partnership based on security and trust is therefore important. Ask the following questions:\u003C\u002Fp>\u003Cul>\u003Cli>Is there willingness to sign an NDA before the first data exchange, such as 3D model, drawing, or specification?\u003C\u002Fli>\u003Cli>How are design data stored and handled after the end of the project?\u003C\u002Fli>\u003Cli>Tool ownership clause: does the tool remain your property, even if it stays at the supplier?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Pass Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>NDA is signed before data exchange, tool remains the property of the customer.\u003C\u002Fp>\u003Cp>\u003Cstrong>Knockout Criterion\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>No NDA, unclear ownership arrangements for the tool.\u003C\u002Fp>\u003Cp>\u003Cstrong>Request Evidence\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>NDA template, tool ownership clause, data deletion and return process.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why formary is the right supplier for your plastic parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>formary is the digital manufacturer for thermoformed plastic parts. Instead of dealing with individual suppliers, you gain access to a network of more than 100 prequalified manufacturers in Germany.\u003C\u002Fp>\u003Cp>\u003Cstrong>You receive a 100% reliable guarantee for these factors from the guide:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Technology and material:\u003C\u002Fstrong> Processes from vacuum forming to pressure forming, roll-fed and sheet-fed production covered in one platform. Materials and machine park are checked against your requirements before every assignment.\u003C\u002Fli>\u003Cli>\u003Cstrong>Industry expertise: \u003C\u002Fstrong>Manufacturers are categorized by industry and references; matching is carried out algorithmically for automotive, medical and pharmaceutical, electronics, and industrial applications.\u003C\u002Fli>\u003Cli>\u003Cstrong>Quality assurance and certifications:\u003C\u002Fstrong> Certificates are checked before manufacturers are admitted to the network. EMPB- or PPAP-capable manufacturers are available for the relevant industries.\u003C\u002Fli>\u003Cli>\u003Cstrong>Delivery reliability: \u003C\u002Fstrong>Backup manufacturers within the same network reduce single-source risk, free capacity is checked before an offer is submitted, and you receive an initial offer within 24 hours.\u003C\u002Fli>\u003Cli>\u003Cstrong>Post-processing from a single source: \u003C\u002Fstrong>Cutting, joining, and surface finishing are bundled through the network, with one contact person responsible for the overall package.\u003C\u002Fli>\u003Cli>\u003Cstrong>Communication: \u003C\u002Fstrong>German-speaking project management throughout the entire project cycle, instead of several parallel supplier contacts.\u003C\u002Fli>\u003Cli>\u003Cstrong>IP protection:\u003C\u002Fstrong> Standardized NDA and secure data exchange are part of the onboarding process.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>You receive an initial offer within 24 hours via the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator.\u003C\u002Fa>\u003C\u002Fp>","supplier-guide-for-plastic-thermoformed-parts",{"id":678,"documentId":679,"createdAt":680,"updatedAt":681,"publishedAt":85,"locale":10,"title":682,"introduction":683,"content":684,"slug":685},353,"mz4e67e1xf14g08lqy7n7mg4","2026-01-13T15:51:48.233Z","2026-06-15T19:24:00.618Z","Rapid Prototyping in Thermoforming – Definition, Benefits & Processes","Rapid prototyping is used in product development to quickly create preliminary models. In thermoforming, rapid prototyping offers numerous advantages for producing high-quality prototypes efficiently and cost-effectively.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid prototyping in deep drawing – the key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Rapid prototyping\u003C\u002Fstrong> in deep-drawing speeds up development and reduces tooling changeover costs.\u003C\u002Fli>\u003Cli>There are \u003Cstrong>four rapid prototyping methods used in deep drawing: \u003C\u002Fstrong>3D printing, urethane, partial-segment moulds and production moulds.\u003C\u002Fli>\u003Cli>Rapid prototyping is used in particular in the \u003Cstrong>sectors\u003C\u002Fstrong> of the automotive, medical technology, robotics and packaging industries.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Do you need rapid prototypes? \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">Enquire now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Rapid Prototyping?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Rapid Prototyping, also known as Fast Prototyping, refers to the process of quickly and efficiently creating physical models or prototypes of a component or assembly based on three-dimensional CAD\u002Fconstruction data. The prototype serves as the first version of the product, which is thoroughly tested and revised if necessary before mass production.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the Purpose of Rapid Prototyping?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Speed:\u003C\u002Fstrong> Rapid Prototyping enables the production of prototypes in the shortest possible time, significantly accelerating the development process.\u003C\u002Fli>\u003Cli>\u003Cstrong>Flexibility:\u003C\u002Fstrong> The process allows for quick modifications and corrections to prototypes, improving the final product.\u003C\u002Fli>\u003Cli>\u003Cstrong>Shorter Time-to-Market:\u003C\u002Fstrong> The production and delivery of prototypes are significantly shortened, allowing products to be launched faster.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Benefits of Rapid Prototyping\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Early detection of design improvements\u003C\u002Fli>\u003Cli>Cost efficiency\u003C\u002Fli>\u003Cli>High precision through computer-aided design\u003C\u002Fli>\u003Cli>Reduced risk of costly errors\u003C\u002Fli>\u003Cli>Ability to present physical prototypes and gather feedback\u003C\u002Fli>\u003Cli>Cost-effective integration of customer requirements\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Types of Rapid Prototyping Methods Exist in Thermoforming?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>There are four primary Rapid Prototyping methods in thermoforming, depending on the purpose of the sample. The following sections provide an overview of these methods.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping with 3D-Printed Molds\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Using 3D-printed \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming molds\u003C\u002Fa> is common for testing critical segments of thermoforming processes. However, due to the high temperatures and mechanical stresses involved in thermoforming, only a small number of samples can be produced from a 3D-printed mold.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:13.2%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Druck_Werkzeug_e31f8571e4.png\" alt=\"Rapid Prototyping mit 3D-Werkzeugen\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">3D-printed prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Cstrong>Maximum number of samples:\u003C\u002Fstrong> 1-3 pieces\u003C\u002Fli>\u003Cli>\u003Cstrong>Production time (best case):\u003C\u002Fstrong> 3-5 working days\u003C\u002Fli>\u003Cli>\u003Cstrong>Cost:\u003C\u002Fstrong> \u003Cspan style=\"color:#005250;\">€€\u003C\u002Fspan>\u003Cspan style=\"color:hsl(0,0%,90%);\">€€€\u003C\u002Fspan>\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Application Areas:\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Testing form-fit accuracy of tray cavities\u003C\u002Fli>\u003Cli>Rapid production of prototypes within a few days\u003C\u002Fli>\u003Cli>Small batch production in standard material\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages vs. Disadvantages of 3D-Printed Molds\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>The benefits of rapid prototyping using 3D printing\u003C\u002Fth>\u003Cth>Disadvantages of rapid prototyping using 3D printing\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>3D-printed tools are often cost-effective\u003C\u002Ftd>\u003Ctd>Depending on the process used, 3D-printed parts have a distinctive surface texture which will be visible on the surface of the deep-drawn part if left untreated. Optical parts are therefore almost automatically ruled out for testing or demonstration purposes. Furthermore, the layered process used in FDM does not allow for the creation of realistic edges and radii, which further diminishes the results’ significance \u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Rapid fit testing of tray mould cavities\u003C\u002Ftd>\u003Ctd>Some materials, such as PP, can only be moulded to the highest standard using temperature-controlled production moulds\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping with Ureol Sample Molds\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Ureol is a moulding material used in model making. Moulds made from Ureol can be used to produce either individual components or the entire finished product. The result often closely resembles mass-produced deep-drawn parts made using aluminium moulds. \u003C\u002Fp>\u003Cp>Although the milling times for producing Ureol moulds are comparable to those for aluminium, the material is more cost-effective. However, due to Ureol’s lower heat and pressure resistance, only a limited number of samples can be produced.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:18.03%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMusterwerkzeug_aus_Ureol_e5f2632c17.png\" alt=\"Rapid Prototyping mit Musterwerkzeugen aus Ureol\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ureol tool prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Cstrong>Maximum number of samples:\u003C\u002Fstrong> 5-10 pieces\u003C\u002Fli>\u003Cli>\u003Cstrong>Production time (best case):\u003C\u002Fstrong> 1-2 weeks\u003C\u002Fli>\u003Cli>\u003Cstrong>Cost:\u003C\u002Fstrong> \u003Cspan style=\"color:#005250;\">€€\u003C\u002Fspan>\u003Cspan style=\"color:hsl(0,0%,90%);\">€€€\u003C\u002Fspan>\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Applications of Ureol tool prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The result is a prototype optimised for 3D printing, which takes only slightly longer to produce and costs only slightly more.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of rapid prototyping using Ureol moulds\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages of rapid prototyping with sample tools made from Ureol\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Disadvantages of rapid prototyping with sample tools made of ureol\u003C\u002Fstrong>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>The samples produced are almost ready for series production, but show slight differences in quality compared to aluminum tools.\u003C\u002Ftd>\u003Ctd>Additional costs: The Ureol tool only serves as an intermediate step prior to the production of the series tool.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>The price is only about 20-30% of the price of a production tool, depending on the contour and complexity of the milling work.\u003C\u002Ftd>\u003Ctd>The series tool is only manufactured after approval, which extends the project schedule by another 2-3 weeks.\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid prototyping using a partial-segment production mould\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A single-cavity aluminium die provides an optimal reproduction of your deep-drawn part and offers cost savings compared to mass production. This can be achieved, for example, by using a simple die instead of a multi-cavity die.\u003C\u002Fp>\u003Cp>\u003Cstrong>Please note:\u003C\u002Fstrong> The prototype mould is an intermediate step towards the production aluminium mould, and the additional time required for its manufacture must be taken into account in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">project planning\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:10.81%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTeilsegment_Serienwerkzeug_ab27e3a164.png\" alt=\"Rapid Prototyping mit Teilsegment-Serienwerkzeug\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Sub-segment production tool prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Maximum number of samples: unlimited\u003C\u002Fli>\u003Cli>Production time (best-case scenario): 2–3 weeks\u003C\u002Fli>\u003Cli>Price: \u003Cspan style=\"color:#00a9a5;\">€€€\u003C\u002Fspan>\u003Cspan style=\"color:#c2c2c2;\">€€\u003C\u002Fspan>\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Areas of application: sub-segment – production tooling and prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Testing a sub-segment using production-specification moulds yields the most realistic indication of the final production result. Where possible, the lessons learnt should be generalisable from the sub-segment to the entire tray.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of rapid prototyping using partial-segment production moulds\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cstrong>Disadvantages\u003C\u002Fstrong>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Closely replicates serial production quality\u003C\u002Ftd>\u003Ctd>Additional production step delays final mold approval by 2-3 weeks\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>More affordable than a full-scale production mold\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Can be adjusted for final production after approval\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid prototyping with series production tools\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The aluminum series production tool is also used to manufacture release samples. The deep-drawn parts produced using this tool are manufactured under optimal conditions in terms of elongation, heat, and cooling behavior.\u003C\u002Fp>\u003Cp>The production rate per unit of time is a decisive factor in terms of price, particularly for medium to high production volumes, which is why large multi-purpose tools are often used.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:29.33%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSerienwerkzeug_edcc0ae7bc.png\" alt=\"Rapid Prototyping mit Serienwerkzeug\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Production tool prototypes\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Maximum number of samples: unlimited\u003C\u002Fli>\u003Cli>Production lead time (best-case scenario): 2–6 weeks (depending on size, design and number of compartments; up to 10 weeks may be required for special components)\u003C\u002Fli>\u003Cli>Price: \u003Cspan style=\"color:#00a9a5;\">€€€€€\u003C\u002Fspan>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cspan style=\"color:#005250;\">Applications of production tool prototypes\u003C\u002Fspan>\u003C\u002Fp>\u003Cp>In terms of production time, production tooling is, of course, the prototyping method that takes the longest. It is therefore primarily used to approve the production product prior to the start of series production – not necessarily for the empirical identification of areas relevant to testing, as with prototype variants 1–3.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of rapid prototyping using production tools\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of rapid prototyping using production tools\u003C\u002Fth>\u003Cth>Disadvantages of rapid prototyping using production tools\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>High-quality production of deep-drawn parts\u003C\u002Ftd>\u003Ctd>Potential costs for reworking the production mould\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>No additional tooling costs before the start of series production\u003C\u002Ftd>\u003Ctd>Production moulds take the longest to manufacture, so it is advisable to opt for a simplified version when samples are needed urgently\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Samples are usually included in the price of the production mould\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Saves time, as no additional approval steps are required\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid prototyping applications\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Rapid prototyping using deep-drawing is used in a wide range of industries, including:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">Automotive:\u003C\u002Fa> Prototypes of vehicle components such as dashboards, door panels and bumpers can be produced quickly and cost-effectively.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">Medical technology:\u003C\u002Fa> The production of prototypes of medical devices and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">housings\u003C\u002Fa> enables manufacturers to develop and test new products quickly.\u003C\u002Fli>\u003Cli>\u003Cstrong>Packaging industry\u003C\u002Fstrong>: Prototypes of packaging and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">plastic containers\u003C\u002Fa> can be produced to test their functionality and aesthetics before they go into mass production.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Frobotics\">Robotics:\u003C\u002Fa> In robotics, the deep-drawing process enables high-speed prototyping, with the ability to make adjustments quickly.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ Would you like to find out more about the applications of thermoformed parts? Then read our article \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fapplications-of-thermoformed-parts\">Thermoformed plastic parts in use.\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid Prototyping in Deep Drawing – A Summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Rapid prototyping in deep drawing offers a wide range of options for producing high-quality prototypes of parts and components \u003Cstrong>quickly and cost-effectively\u003C\u002Fstrong>. By combining speed and flexibility, the rapid prototyping process streamlines product development and enables formary to bring innovative products to market more quickly. \u003C\u002Fp>\u003Cp>Get in touch with us \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">now\u003C\u002Fa>! \u003C\u002Fp>","rapid-prototyping-in-thermoforming",{"id":687,"documentId":688,"createdAt":689,"updatedAt":690,"publishedAt":85,"locale":10,"title":691,"introduction":692,"content":693,"slug":694},344,"it056tjampj9j84may9sx026","2026-01-13T15:51:46.463Z","2026-06-02T17:45:24.038Z","Cleanroom Manufacturing of Thermoformed Plastic Parts – High Hygiene Standards","Cleanroom manufacturing of thermoformed plastic parts plays a crucial role in industries where stringent sterility requirements are essential. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom manufacturing of plastic thermoformed parts – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Cleanroom manufacturing prevents particle contamination and guarantees the highest level of product purity.\u003C\u002Fli>\u003Cli>Thermoformed plastic parts produced in cleanrooms are used in the medical, electronics, aerospace and automotive industries.\u003C\u002Fli>\u003Cli>International standards such as ISO 14644 and EU GMP define the permissible particle levels.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Enquire about cleanroom thermoformed parts now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Cleanroom Manufacturing?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Cleanroom manufacturing, cleanroom production or cleanroom technology enables the manufacture of high-quality, bespoke components for use in sensitive environments such as the \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">\u003Cspan style=\"color:hsl(0,0%,0%);\">medical technology\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:hsl(0,0%,0%);\">, \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">\u003Cspan style=\"color:hsl(0,0%,0%);\">electronics\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:hsl(0,0%,0%);\"> and \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Faerospace-defense\">\u003Cspan style=\"color:hsl(0,0%,0%);\">aerospace industries\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:hsl(0,0%,0%);\">.\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FArbeiten_im_Reinraum_2a8a3215c7.jpg\" alt=\"Arbeiten im Reinraum\">\u003Cfigcaption>Working in a cleanroom\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is the purpose of cleanroom manufacturing?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Cleanroom manufacturing is designed to ensure that products are not contaminated by particles in the ambient air. A cleanroom is an area with a low concentration of airborne particles. Airborne particles are particles that float in the air and are sometimes invisible to the naked eye.\u003C\u002Fspan>\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is a Cleanroom?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A cleanroom is a specially designed space that is continuously monitored and regulated to ensure the highest level of purity and precision in production. Cleanroom manufacturing follows strict standards for air quality, particle concentration, and environmental conditions.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What are the Requirements for a Cleanroom?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A critical aspect of cleanroom manufacturing for thermoformed plastic parts is the use of specialized materials. These materials must meet the stringent requirements of the thermoforming process while also complying with cleanroom purity standards. Some requirements include:\u003C\u002Fp>\u003Cul>\u003Cli>The use of low-particle-emission plastics\u003C\u002Fli>\u003Cli>Special coatings or treatments to minimize contamination\u003C\u002Fli>\u003Cli>Strict adherence to hygiene protocols\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is allowed in a cleanroom?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In einen Reinraum dürfen nur Personen, Materialien und Ausrüstungen, die den festgelegten Reinheitsstandards entsprechen. In der Reinraumproduktion zu arbeiten, schließt spezielle Reinraumkleidung, Werkzeuge und Filtereinrichtungen ein.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Thermoforming Process in Cleanroom Manufacturing \u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSchutzvorkehrungen_fuer_die_Reinraumfertigung_1c833cca1e.jpg\" alt=\"Schutzvorkehrungen bei der Reinraumfertigung\">\u003Cfigcaption>Precautions for cleanroom manufacturing\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic deep-drawing\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">plastic sheets\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">films\u003C\u002Fa> are shaped into a three-dimensional form. The plastic is formed in a cleanroom under controlled conditions to ensure that no harmful particles or contaminants enter the manufactured plastic parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Significance for sensitive applications\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Cleanroom manufacturing is particularly important for implants, electronic components and aerospace components. Even the tiniest particles of contamination can have serious consequences in these contexts, which is why strict safety precautions must be observed.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Why Manufacture Thermoformed Plastic Parts in a Cleanroom?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Reliable functional safety is important in sensitive areas such as medicine and pharmaceuticals, electronics, and food. Specific plastic products are manufactured in cleanroom production to prevent airborne dirt particles from interfering with the production of supplier parts.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2500\u002F500;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMedizinische_Tiefziehteile_die_mit_Reinraumfertigung_hergestellt_wurden_7a1e92194f.png\" alt=\"Tiefziehteile für die Medizin, die im Reinraum hergestellt wurden\" width=\"2500\" height=\"500\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of plastic thermoformed parts manufactured in cleanroom production\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Optimal cleanliness:\u003C\u002Fstrong> The controlled cleanroom environment ensures that the cleanroom products manufactured are free of contamination.\u003C\u002Fli>\u003Cli>\u003Cstrong>Versatile applications:\u003C\u002Fstrong> Thermoformed parts manufactured in cleanroom production are used in sensitive areas such as medicine, electronics, and aerospace.\u003C\u002Fli>\u003Cli>\u003Cstrong>Improved reliability:\u003C\u002Fstrong> The elimination of contamination in the cleanroom increases the reliability and performance of the thermoformed parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Regardless of cleanroom production, the manufacture of plastic parts using the thermoforming process enables exceptional precision and tight tolerances. Thermoformed parts are therefore ideal for demanding applications that require complex geometries.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production is essential for these end markets in plastic thermoformed parts.\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Semiconductor manufacturing\u003C\u002Fli>\u003Cli>Optical and laser technology\u003C\u002Fli>\u003Cli>Aerospace\u003C\u002Fli>\u003Cli>Life sciences\u003C\u002Fli>\u003Cli>Medical treatment and research\u003C\u002Fli>\u003Cli>Manufacture of sterile implants, wound dressings, thermoformed trays, and other medical assemblies\u003C\u002Fli>\u003Cli>Germ-free production of pharmaceuticals and food\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production for the automotive industry\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Cleanroom production is also becoming increasingly important for the automotive industry. It enables automotive manufacturers and suppliers to ensure that parts and components are manufactured to the highest cleanliness standards. Cleanliness requirements are particularly critical in sensitive vehicle parts such as ABS or direct injection systems. These components are extremely sensitive to contamination, especially particle residues.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoff_Tiefziehteile_fuer_Automotive_752244652f.webp\" alt=\"Kunststoff Tiefziehteile für Automotive\">\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">VDA 19: Technical Cleanliness in the Automotive Industry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cstrong>VDA 19\u003C\u002Fstrong>, or more specifically VDA 19.1, is a guideline developed specifically for the automotive industry to ensure the technical cleanliness of functionally critical automotive parts. This guideline was established to meet the need for industry-wide standards and testing methods.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Application of VDA 19 in the production process\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>VDA 19.1 defines requirements for clean manufacturing and the inspection of components. It is applied at various stages of the production process, such as:\u003C\u002Fp>\u003Cul>\u003Cli>Initial sampling of components\u003C\u002Fli>\u003Cli>Outgoing and incoming inspection\u003C\u002Fli>\u003Cli>Quality control for manufacturing processes involving cleanliness\u003C\u002Fli>\u003Cli>Monitoring of process steps\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n.c-container {\nborder: 2px solid #15A9A4;\npadding: 10px;\nmargin: 10px;\nborder-radius: 10px;\n}\n\n.c-container {\nmargin: 0;\n}\n\u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n\u003Cp>ℹ️ \u003Cb>E-mobility:\u003C\u002Fb> Cleanroom manufacturing plays a crucial role in the context of e-mobility in the automotive industry. The use of cleanroom technologies ensures a clean and precise manufacturing environment that meets the high demands of assembling batteries, power electronics, and other key components. \u003C\u002Fp>\n\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Combination of cleanroom manufacturing and VDA 19\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The combination of cleanroom manufacturing and the requirements of VDA 19 provides a clear framework for the production of high-quality, technically clean automotive parts. This helps minimize failures and enhance vehicle safety.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Most important cleanroom classes according to various standards\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>For semiconductor technology \u003Cstrong>ISO 14644-1\u003C\u002Fstrong> and \u003Cstrong>2\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>For aerospace technology also \u003Cstrong>ISO 14644\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>In food technology according to standard \u003Cstrong>VDI 2083\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>In the pharmaceuticals guideline \u003Cstrong>EU-GMP\u003C\u002Fstrong> with \u003Cstrong>Annex 1\u003C\u002Fstrong>\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Classes in cleanroom manufacturing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The cleanroom classes with all their conditions are listed here again with all the most important cleanroom guidelines:\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Purity classes according to ISO 14644-1\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Cleanroom classified according to ISO 1-9\u003C\u002Fli>\u003Cli>Cleanroom classes may only contain a particle count between 0.1 µm and 5 µm\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Cleanliness classes according to EU-GMP guideline Annex 1\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>GMP guideline defines cleanroom classes according to A, B, C, and D\u003C\u002Fli>\u003Cli>Here, only the maximum permitted particles per cubic meter are differentiated according to sizes greater than or equal to 0.5 µm and greater than or equal to 5 µm\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">VDI Guideline 2083 – Definition and function of a cleanroom\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Defines how a cleanroom is defined, how it works, and what needs to be considered\u003C\u002Fli>\u003Cli>The guideline deals exclusively with permissible concentrations of particles in the air at the so-called clean workplace\u003C\u002Fli>\u003Cli>As with DIN EN ISO 14644, only particles in the size range between 0.1 µm and 5 µm are considered\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">How can formary guarantee sterile conditions for cleanroom production?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>formary has access to a network of partners that enables cleanroom production and additional hygiene levels, allowing us to meet all hygiene standards for thermoformed parts. Use the configurator to request your individual thermoformed part under cleanroom conditions now.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:38.84%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FLaptop_Mockup_mit_formary_Plattform_0ef57233fa.png\" alt=\"Laptop Mockup mit formary Plattform\" width=\"1920\" height=\"1080\">\u003Cfigcaption>formary Plattform\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ Do you want to know how the quality processes work at formary? Learn more here about the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fquality-assurance\">quality assurance\u003C\u002Fa> of our suppliers and post-processors.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production for plastic thermoformed parts – a summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Cleanroom manufacturing of plastic thermoformed parts plays a key role in industries that demand the highest quality standards and cleanliness requirements. Working in a cleanroom not only ensures the production of hygienic and clean parts, but also helps improve the reliability and performance of products in sensitive applications.\u003Cbr>Through its specialized supply network, formary ensures that, for every industry requiring high hygiene standards, the appropriate manufacturers design and produce the thermoformed parts.\u003C\u002Fp>\u003Cp>\u003Cstrong>Do you have any further questions? Feel free to give us a call at \u003C\u002Fstrong>\u003Cspan style=\"color:#005250;\">\u003Cstrong>+49 7191 9525170!\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ Thermoformed blisters in medical technology also benefit from high hygiene standards. Find out more here in our\n \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Frelevance-of-thermoformed-blisters-in-medical-technology\"> Whitepaper \u003C\u002Fa> On the relevance of medicine blister packs in medical technology.\n\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>","cleanroom-manufacturing-of-themoformed-parts",{"id":696,"documentId":697,"createdAt":698,"updatedAt":699,"publishedAt":85,"locale":10,"title":700,"introduction":701,"content":702,"slug":703},375,"y6dpnh7b8vjzkuer2g0gjqbq","2026-01-13T15:51:52.410Z","2026-06-15T19:15:31.357Z","Injection Molding vs. Plastic Thermoforming – Advantages, Disadvantages, Differences, and Similarities","In the world of plastic processing, there are various common manufacturing methods used to produce precise plastic components for industrial applications. We compare two of them: Injection Molding and Plastic Thermoforming.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Injection Molding vs. Plastic Thermoforming – Key Facts at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Costs & Volume:\u003C\u002Fstrong> Thermoforming is cost-effective for small to medium production runs due to its low tooling costs, starting from around 5 units. Injection molding requires high upfront investment in tooling but becomes highly economical in mass production thanks to extremely low unit costs, typically from 10,000 units upward.\u003C\u002Fli>\u003Cli>\u003Cstrong>Precision & Complexity:\u003C\u002Fstrong> Injection molding enables very high precision and the production of complex geometries with details such as hooks or ribs. Thermoforming is better suited for large, less complex parts and generally has wider tolerances.\u003C\u002Fli>\u003Cli>\u003Cstrong>Lead Time:\u003C\u002Fstrong> Thermoforming tools can be produced quickly, usually within a few weeks, resulting in short lead times. Injection molding tools are significantly more complex to manufacture and can take several months.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>For a quick overview, you can also watch the related video:\u003C\u002Fp>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=3f-yisGW3z0\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Injection Molding?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Injection molding is a widely used manufacturing process for producing plastic parts. It involves injecting molten plastic into a mold - hence the name. The plastic solidifies through hydraulic cooling, and once the mold opens, the finished part is ejected. But how exactly does the injection molding process work? Let's break it down.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1664\u002F945;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FInjection_Molding_Process_01c63014a2.webp\" alt=\"Injection Molding Process\" width=\"1664\" height=\"945\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does the Injection Molding Process Work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Col>\u003Cli>\u003Cstrong>Melting the Plastic:\u003C\u002Fstrong> Plastic granules are heated until they become liquid. The mold, also known as the injection mold tool, is closed. This two-part mold forms the negative shape of the desired end product.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injecting the Molten Plastic:\u003C\u002Fstrong> The liquefied plastic is injected under high pressure into the closed mold, filling its cavities and taking its shape.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling and Solidification:\u003C\u002Fstrong> The injected plastic is cooled from the inside using water, causing it to solidify into a stable form.\u003C\u002Fli>\u003Cli>\u003Cstrong>Ejecting the Part:\u003C\u002Fstrong> Once solidified, the mold opens, and the finished injection-molded part is removed.\u003C\u002Fli>\u003C\u002Fol>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Plastic Thermoforming?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">Plastic thermoforming,\u003C\u002Fa> also known as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">vacuum forming,\u003C\u002Fa> is a process in which thermoplastic sheets are heated, reshaped using forming machines, and cut into the desired shape by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fseparating\">stamping or milling.\u003C\u002Fa> This method enables the production of three-dimensional plastic parts with various shapes and sizes, tailored to specific applications.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ In addition to classic plastic thermoforming, also known as the single-sheet process, there is also twin-sheet thermoforming, in which two plastic films or sheets are heated simultaneously. You can find more information in our blog article on the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftwin-sheet-process\">twin-sheet process.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Cp>\u003Ci>ℹ️ In addition to classic plastic thermoforming, also known as the single-sheet process, there is also twin-sheet thermoforming, in which two plastic films or sheets are heated simultaneously. You can find more information in our blog article on the \u003C\u002Fi>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftwin-sheet-process\">\u003Ci>twin-sheet process.\u003C\u002Fi>\u003C\u002Fa>\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does the Thermoforming Process Work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Plastic thermoforming works in this way:\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:44.14%;\">\u003Cimg style=\"aspect-ratio:1200\u002F1697;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FThermoforming_Process_18eb4a1d37.webp\" alt=\"Thermoforming Process\" width=\"1200\" height=\"1697\">\u003Cfigcaption>Plastic Thermoforming Process\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Col>\u003Cli>\u003Cstrong>Heating:\u003C\u002Fstrong> The thermoplastic sheet is heated to its forming temperature, where it becomes elastic and moldable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Forming:\u003C\u002Fstrong> The softened sheet is stretched over a mold. It is secured in a frame and shaped using vacuum pressure or mechanical force. This process usually takes only a few seconds.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling:\u003C\u002Fstrong> The material cools upon contact with the mold, stabilizing its shape.\u003C\u002Fli>\u003Cli>\u003Cstrong>Trimming:\u003C\u002Fstrong> Once cooled, excess material is removed using stamping or milling processes.\u003C\u002Fli>\u003C\u002Fol>\u003Ch2>\u003Cspan style=\"color:#005250;\">Injection Molding vs. Thermoforming: Key Differences\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Ideal for small to medium quantities, e.g. covers, trim parts or packaging.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injection molding:\u003C\u002Fstrong> Economical for high volumes starting from 10,000 units, e.g. technical components or mass-produced products.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Some thermoformed products, such as yogurt cups, can even be manufactured in \u003Cstrong>quantities of millions\u003C\u002Fstrong>.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">General Comparison between Injection Molding and Thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Factor\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Thermoforming\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Injection Molding\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Production Volume\u003C\u002Ftd>\u003Ctd>Medium > 5\u003C\u002Ftd>\u003Ctd>Hoch > 10.000\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Delivery Time\u003C\u002Ftd>\u003Ctd>Weeks\u003C\u002Ftd>\u003Ctd>Months\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Tooling Costs\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Tolerances\u003C\u002Ftd>\u003Ctd>-\u003C\u002Ftd>\u003Ctd>++\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Cost Comparison: Thermoforming vs. Injection Molding\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In thermoforming, the initial investment is significantly lower than in injection molding. This is due to the single-sided tool design, as no cavity is required.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming tools:\u003C\u002Fstrong> approx. €500–10,000, or more for large parts.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injection molding tools:\u003C\u002Fstrong> from €20,000 upwards, even for smaller parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ \u003Cb>Important to note:\u003C\u002Fb>  Once the thermoforming tool has been made from production-grade material, such as aluminum, it can be scaled to very high volumes, that can often go well into the six-figure range without rework.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Lead times in comparison\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Tools can be manufactured within 1–2 weeks.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injection molding:\u003C\u002Fstrong> Standard tools require at least 10 weeks of manufacturing time.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Tolerances and accuracy\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Tolerances are usually around ±1 mm, according to ISO 2768-c for nominal lengths of 120–400 mm.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injection molding:\u003C\u002Fstrong> Very tight tolerances are possible, typically ±0.1 mm, and even down to ±0.025 mm for precision parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>Conclusion:\u003C\u002Fstrong> Thermoforming is more cost-effective and faster for smaller quantities, while injection molding is better suited for high precision and large-scale production.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of injection molding\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Injection molding makes it possible to produce a \u003Cstrong>high number of\u003C\u002Fstrong> precise plastic parts. Continuous consistency and repeatability are crucial, especially when producing large quantities of plastic components, and these are precisely the aspects that the injection molding process guarantees. Despite the many advantages offered by the injection molding process, there are also some potential disadvantages to consider.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Overview of the possibilities and limitations of the injection molding process\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of injection molding\u003C\u002Fspan> \u003C\u002Fp>\u003C\u002Fth>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of injection molding\u003C\u002Fspan> \u003C\u002Fp>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Low unit costs for mass production\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">High tooling costs \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">High precision and reproducibility \u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Comparatively high wear on tools \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Suitable for complex shapes and contours such as hooks, combs, and ribs\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Thin-walled parts often more expensive than deep drawing \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">High surface quality\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">High energy consumption \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Injection molded parts do not require reworking\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Design changes are expensive \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Process can be fully automated\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Long lead times \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of plastic thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Plastic thermoforming is economically attractive especially for medium-sized series and short lead times. Low \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">tooling costs\u003C\u002Fa> and a wide material selection make it particularly flexible.\u003C\u002Fp>\u003Cp>However, it is important to note that, unlike injection molding, the tool in the thermoforming process only has contact with the material on one side, which entails certain geometric restrictions. More on this in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fdesign-guide\">Design Guide.\u003C\u002Fa>\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Overview of the possibilities and limitations of plastic thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of plastic thermoforming\u003C\u002Fspan>\u003C\u002Fp>\u003C\u002Fth>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of plastic thermoforming\u003C\u002Fspan> \u003C\u002Fp>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Low investment costs for tools \u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Tool adjustments can be expensive \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Cost-effective production\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Slightly slower manufacturing process than injection molding \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Worthwhile even for small quantities \u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Complex shapes with very thin walls are limited \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Optimal options for post-processing\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Potential difficulty in achieving uniform material thicknesses in complex shapes \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Post-industrial recycling possible for simple cycles \u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">One-sided material contact \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Unrivaled for thin-walled parts\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">More complex geometries from the injection molding sector cannot be produced \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Short lead times\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Semi-finished products more expensive than with injection molding \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Large selection of materials\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Cutting and punching costs \u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">All sizes and shapes possible (large parts)\u003C\u002Fp>\u003C\u002Ftd>\u003Ctd>\u003Cp style=\"text-align:center;\">Potential sources of error in semi-finished product manufacturing due to frozen stresses in the material during extrusion\u003C\u002Fp>\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Similarities between Plastic Thermoforming and Injection Molding\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Whether produced by thermoforming or injection molding, plastic products share certain properties that make them attractive for many industries.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Key advantages of plastic parts\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Low weight:\u003C\u002Fstrong> Due to their lower density \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastics-vs-metal\">compared to metals\u003C\u002Fa>, plastic parts are lighter and more efficient, for example in vehicles.\u003C\u002Fli>\u003Cli>\u003Cstrong>Durability:\u003C\u002Fstrong> Many plastics are robust and retain their function even after long periods of use.\u003C\u002Fli>\u003Cli>\u003Cstrong>Corrosion resistance:\u003C\u002Fstrong> Thermoplastics are hardly affected by moisture or chemicals, making them particularly durable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Electrical insulation:\u003C\u002Fstrong> Plastic provides reliable insulation; with special materials such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD trays\u003C\u002Fa>, it can even protect against electrostatic discharge.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Areas of Application for Injection Molding and Plastic Thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Some products can be manufactured using either injection molding or thermoforming, provided the geometry is adapted accordingly. The choice between thermoforming and injection molding depends on the specific product requirements, materials, production volume and costs.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industries with overlapping applications\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Both injection molding and thermoforming are used in many industries:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fthermoformed-plastic-packaging\">\u003Cstrong>Packaging\u003C\u002Fstrong>\u003C\u002Fa>\u003Cstrong>:\u003C\u002Fstrong> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">Plastic containers,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">trays,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">covers and housings.\u003C\u002Fa> Closures such as hinged lids can also be manufactured using both processes.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">\u003Cstrong>Automotive:\u003C\u002Fstrong>\u003C\u002Fa> Interior trim, door panels, dashboards and covers. The decision depends on design and cost requirements.\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">\u003Cstrong>Medical technology:\u003C\u002Fstrong>\u003C\u002Fa> Plastic containers for laboratory samples, as well as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">medical device housings,\u003C\u002Fa> for example for surgical lights or MRI systems. Thermoforming is becoming increasingly important in this field. → Read more in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fthermoformed-medical-devices-guide\">medical technology guide.\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">\u003Cstrong>Electronics:\u003C\u002Fstrong>\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">Plastic housings\u003C\u002Fa> for remote controls, gadgets or small appliances can be produced using either process.\u003C\u002Fli>\u003Cli>\u003Cstrong>Consumer goods:\u003C\u002Fstrong> Plastic plates, bowls and cups are manufactured by injection molding or thermoforming depending on geometry and cost requirements.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCover_Housing_Container_c6cdbd2d05.webp\" alt=\"Cover_Housing_Container\">\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typical applications for injection molding\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Injection molding is particularly worthwhile when precise and complex geometries are required in large quantities:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Delicate small parts:\u003C\u002Fstrong> e.g. lipstick tubes, toy figures, screws, nuts, clips or switches.\u003C\u002Fli>\u003Cli>\u003Cstrong>Automotive components:\u003C\u002Fstrong> Switch covers, trim parts, buttons and brackets.\u003C\u002Fli>\u003Cli>\u003Cstrong>Electrical housings:\u003C\u002Fstrong> For mobile phones, laptops, televisions or cameras.\u003C\u002Fli>\u003Cli>\u003Cstrong>Medical devices:\u003C\u002Fstrong> Housings for infusion pumps, diagnostic devices or precise plastic components.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typical applications for thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The thermoforming process offers advantages when lower tooling costs, thin-walled components and flexible modifiability are required:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Thermoformed trays:\u003C\u002Fstrong> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">Plastic trays\u003C\u002Fa> and returnable packaging for transport and logistics.\u003C\u002Fli>\u003Cli>\u003Cstrong>Blister packaging:\u003C\u002Fstrong> For pharmaceuticals, food or consumer goods; cost-effective and suitable for large-scale production.\u003C\u002Fli>\u003Cli>\u003Cstrong>Automotive trim parts:\u003C\u002Fstrong> Thin-walled components such as interior trim or storage compartments to reduce weight and costs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Covers and housings:\u003C\u002Fstrong> For \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmachine-covers\">machines\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Frobotics\">robotics \u003C\u002Fa>or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fprototyping\">prototypes,\u003C\u002Fa> especially for smaller quantities.\u003C\u002Fli>\u003Cli>\u003Cstrong>Inlays:\u003C\u002Fstrong> Inserts for cases, drawers or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-cosmetic-packaging\">cosmetic packaging.\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FInlay_Cover_Blister_60a2ce6a02.webp\" alt=\"Inlay_Cover_Blister\">\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic thermoforming or injection molding? – Conclusion and recommendations\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The choice between injection molding and thermoforming depends on various factors. Tooling costs, geometries, production volumes and lead times all need to be weighed when deciding between the two processes.\u003C\u002Fp>\u003Cp>For comparatively low investment costs, production volumes of 5–10,000 units and short lead times, plastic thermoforming is the optimal solution. In any case, a detailed analysis of the requirements is important in order to make the best possible decision.\u003C\u002Fp>\u003Cp>Do you have questions about thermoforming? Feel free to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact us\u003C\u002Fa> — we’ll be happy to support you with your \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">thermoforming project planning\u003C\u002Fa>.\u003C\u002Fp>","injection-molding-vs-thermoforming",{"id":381,"documentId":705,"createdAt":706,"updatedAt":707,"publishedAt":85,"locale":10,"title":708,"introduction":709,"content":710,"slug":711},"pocmz2z9l3ht47z25g69f626","2026-01-13T15:51:49.526Z","2026-06-03T09:14:01.115Z","Thermoforming vs. 3D Printing – Advantages, Disadvantages, Differences, and Similarities","Plastic parts are manufactured using various processing methods. In this article, we focus on comparing the processes of plastic thermoforming and 3D printing.","\u003Ch2>Thermoforming vs. 3D Printing - The Essentials in Brief\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming\u003C\u002Fstrong> is suitable for cost-effective series production of large plastic parts with flexible shapes and high material efficiency.\u003C\u002Fli>\u003Cli>\u003Cstrong>3D printing\u003C\u002Fstrong> is ideal for prototypes, small series and complex components without tooling, but slower and with limited material choice.\u003C\u002Fli>\u003Cli>Thermoforming is worthwhile for medium to high volumes, 3D printing primarily for customized or quickly needed parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ For a quick overview, we recommend our video on the same topic:\u003C\u002Fp>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=X0TWpHl23sk\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does Thermoforming Work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoforming\u003C\u002Fa>, also known as plastic deep-drawing, thermoplastic plastics are formed by heating using thermoforming machines. After cooling, the desired shape is cut by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fseparating\u002Fshear-cutting\">punching\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fseparating\u002Fcnc-milling\">milling\u003C\u002Fa>.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>.c-container {border: 2px solid #15A9A4;padding: 10px;margin: 10px;border-radius: 10px;}.c-container {margin: 0;}\u003C\u002Fstyle>\u003Cdiv class=\"c-container\"> \u003Cp> ℹ️ In addition to classic plastic thermoforming, also known as the single-sheet process, there is also twin-sheet thermoforming, in which two plastic films\u002Fsheets are heated simultaneously. For more information, see our blog post on the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftwin-sheet-process\">twin-sheet process.\u003C\u002Fa> \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:39.57%;\">\u003Cimg style=\"aspect-ratio:1200\u002F1697;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FThermoforming_Process_18eb4a1d37.webp\" alt=\"Thermoforming Process\" width=\"1200\" height=\"1697\">\u003Cfigcaption>Thermoforming on a negative mold\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">The Thermoforming Process\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>This is how the process of thermoforming plastics works:\u003C\u002Fp>\u003Col>\u003Cli>\u003Cstrong>Heating:\u003C\u002Fstrong> During the heating process, the thermoplastic is heated to the so-called forming temperature. At this stage, the plastic shows rubber-elastic behavior.\u003C\u002Fli>\u003Cli>\u003Cstrong>Forming:\u003C\u002Fstrong> During the forming process, the semi-finished product is stretched into the desired shape. The material is clamped in a frame and positioned on the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa>. The entire process usually takes only a few seconds.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling:\u003C\u002Fstrong> After the semi-finished product has made contact with the tool, the cooling process begins. Cooling occurs through contact of the tool-side material surface with the aluminum surface.\u003C\u002Fli>\u003Cli>\u003Cstrong>Separation:\u003C\u002Fstrong> After the thermoformed part has cooled, the next step is demolding. Various separation methods, which can be divided into punching and milling, are used to remove the material remnants.\u003C\u002Fli>\u003C\u002Fol>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is 3D printing?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cstrong>3D printing definition:\u003C\u002Fstrong> 3D printing, also known as \u003Cstrong>additive manufacturing (AM)\u003C\u002Fstrong>, begins with the creation of a digital 3D model, which is divided into thin horizontal layers - a process known as \"slicing\". The 3D printer then builds the object layer by layer by applying material such as plastic.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">A brief look at the history of 3D printing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The 3D printing process was invented in the early 1980s and has therefore existed for about four decades. Originally, 3D printing was a slow and expensive manufacturing method. However, thanks to extensive technological developments, 3D printing technology has evolved into a process that finds applications in various industries.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What 3D printing processes are there?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>3D printing is a versatile plastic processing method, which in turn can be divided into several printing processes. Three important ones are the following:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">SLS - Selective Laser Sintering\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In this 3D printing process, a laser selectively fuses plastic powder particles. This creates a three-dimensional component layer by layer. One advantage here is that the residual powder can be reused.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">SLA - Stereolithography\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>3D printing process with SLA: A laser is used here and cures the part from liquid resin. This process offers the highest precision, but limited material selection.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">FDM - Fused Deposition Modeling\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The printing material required for this is heated in the 3D printer and the object is built up layer by layer along the path. Once printing is complete, support structures or support materials must be removed from the object, if present.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does 3D Printing Work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Here is a simplified breakdown of the FDM 3D printing process:\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.13%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fschritt1_4164e21477.png\" alt=\"3D Druck - Vorbereitung Druckbett \">\u003Cfigcaption>3D printing material preparation\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.41%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fschritt2_678986dfc9.png\" alt=\"3D-Druck Material Aufheizen \">\u003Cfigcaption>Heating up the 3D printer\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.19%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fschritt3_802f958beb.png\" alt=\"3D Druck auftragen der Schichten\">\u003Cfigcaption>Applying the layers\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.18%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F4_d0fbc2e860.png\" alt=\"3D Druck Auskühlen und härten\">\u003Cfigcaption>Cooling and hardening\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Col>\u003Cli>\u003Cstrong>Material preparation:\u003C\u002Fstrong> The 3D printer is loaded with the appropriate plastic material. The printing parameters, such as printing temperature and speed, are set according to the material requirements. The print bed is prepared and, if necessary, treated with special adhesives to ensure good adhesion of the material during the printing process.\u003C\u002Fli>\u003Cli>\u003Cstrong>Heating the 3D printer:\u003C\u002Fstrong> The 3D printer is heated to the required temperature to bring the material into a liquid or at least easily malleable state.\u003C\u002Fli>\u003Cli>\u003Cstrong>Applying the layers:\u003C\u002Fstrong> The 3D printer continues building the object layer by layer, placing or solidifying each layer over the previous one. This layer-by-layer construction continues until the entire object is printed.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling and hardening:\u003C\u002Fstrong> After the printing process, the printed object is cooled and hardened to achieve its final strength. If necessary, post-processing steps can be carried out after the printing process, such as removing support structures or smoothing surfaces.\u003C\u002Fli>\u003C\u002Fol>\u003Ch2>\u003Cspan style=\"color:#005250;\">The differences between thermoforming and 3D printing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoforming and 3D printing are two completely different processes for manufacturing plastic parts. While thermoforming is mainly used for series production, 3D printing is primarily suitable for prototypes and small series.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Comparison of the two processes\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\" style=\"width:auto;\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth style=\"padding:4px 8px;\">Factors\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">Thermoforming\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">3D Printing\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Volume\u003C\u002Ftd>\u003Ctd>Medium > 5\u003C\u002Ftd>\u003Ctd>Low < 5\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Lead time\u003C\u002Ftd>\u003Ctd>Weeks\u003C\u002Ftd>\u003Ctd>Days\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Tooling costs\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003Ctd>No tooling needed\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Tolerances\u003C\u002Ftd>\u003Ctd>-\u003C\u002Ftd>\u003Ctd>-to++\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Volumes in comparison\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>3D printing:\u003C\u002Fstrong> Typical in the prototyping area, lead times are often only a few days. For large series, 3D printing is limited due to slower production speed, poor scalability and higher material cost share.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Due to the tool design, the thermoforming process is scalable for \u003Cstrong>volumes from 5 to millions\u003C\u002Fstrong>. Production takes place at high cycle speeds and is therefore also suitable for mass production.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Tooling costs and lead times\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>3D printing:\u003C\u002Fstrong> No tooling required → therefore there are \u003Cstrong>no lead times\u003C\u002Fstrong>. As soon as the CAD data is available, parts can be manufactured within a few days.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Requires a tool, which costs \u003Cstrong>500-10,000 €\u003C\u002Fstrong> depending on the design (for large parts also more). Tool production usually takes several weeks, in the best case 1-2 weeks.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Production time\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>3D printing:\u003C\u002Fstrong> The parts can be produced practically \"overnight\" after the design is approved.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> Dependent on tooling. Initial sampling usually takes several weeks.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Tolerances\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming:\u003C\u002Fstrong> In most industrial and packaging applications ± 1 mm according to ISO 2768-c (for components from 120-400 mm).\u003C\u002Fli>\u003Cli>\u003Cstrong>3D printing:\u003C\u002Fstrong> Depending on the process, e.g. ±0.2% for SLA and ±0.5% for FDM.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ More information about thermoforming volumes, lead times and more can be found in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fdesign-guide\">Design Guide.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Possibilities and limitations of thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoforming proves to be an extremely cost-effective option, even when producing large volumes. This is partly due to fast and cost-effective production, low tooling costs, high material efficiency and flexible shaping. The large selection of materials, additives and surface finishes of the semi-finished products also make thermoforming an extremely attractive solution in various industries.\u003Cbr>The disadvantage - depending on the series size - lies in the necessary investment in a tool.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of thermoforming Disadvantages of thermoforming\u003C\u002Fspan>\u003C\u002Fth>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of thermoforming\u003C\u002Fspan>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Low investment costs for tools\u003C\u002Ftd>\u003Ctd>Tool adjustments can be expensive\u003Cbr> \u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cost-effective production\u003C\u002Ftd>\u003Ctd>Potential sources of error in semi-finished product manufacturing due to frozen stresses in the material during extrusion\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Worthwhile even for small quantities\u003C\u002Ftd>\u003Ctd>Complex shapes with very thin walls are limited\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Optimal options for post-processing\u003C\u002Ftd>\u003Ctd>Potential difficulty in achieving uniform material thicknesses in complex shapes\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Post-industrial recycling possible for simple cycles \u003C\u002Ftd>\u003Ctd>One-sided material contact\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Unrivaled for thin-walled parts\u003C\u002Ftd>\u003Ctd>More complex geometries cannot be produced using 3D printing\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Short lead times\u003C\u002Ftd>\u003Ctd>Semi-finished products more expensive than with 3D printing\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Large selection of materials \u003C\u002Ftd>\u003Ctd>Cutting and punching costs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>All sizes and shapes possible (large parts)\u003C\u002Ftd>\u003Ctd>Complex geometries that cannot be produced using 3D printing\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the advantages and disadvantages of 3D printing?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>3D printing is particularly suitable for the production of complex prototypes and small series. However, compared to thermoforming, it also brings some limitations.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D printing advantages\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>3D printing enables the production of complex, customized parts with high precision and minimal material waste or material scrap. This leads to material and cost savings for smaller volumes or prototype development. In addition, the need for expensive molds or tools for production is eliminated, which reduces the initial investment.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D printing disadvantages\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>3D printing is generally slower and less cost-effective when producing large volumes. The limited material selection and strength can also mean that 3D printing is not suitable for all applications. In addition, due to the layer structure of the parts, time-consuming post-processing may be necessary, which requires time and resources.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Comparison to thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In comparison, a thermoformed part can often be used without additional grinding, polishing or painting work. The appropriate finish can be achieved directly with the material or by introducing an imprint of the desired surface structure in the tool.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of 3D printing\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of 3D Printing\u003C\u002Fth>\u003Cth>Disadvantages of 3D Printing\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>No tooling costs\u003C\u002Ftd>\u003Ctd>Low quantities\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Short delivery times\u003C\u002Ftd>\u003Ctd>Slow manufacturing process\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Complex shapes possible\u003C\u002Ftd>\u003Ctd>Limited material selection\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>No long setup times & tool changes\u003C\u002Ftd>\u003Ctd>Surface may require post-processing\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>No tool adjustments\u003C\u002Ftd>\u003Ctd>Component size limited\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Constant price per part\u003C\u002Ftd>\u003Ctd>Manufacturing process is more prone to errors, especially with complex components\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Shortened production time for prototypes\u003C\u002Ftd>\u003Ctd>Slightly larger manufacturing tolerances\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u002F\u003C\u002Ftd>\u003Ctd>Low material efficiency → necessary support structures\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">3D printing possibilities and application areas\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The 3D printing process offers diverse application possibilities, ranging from prototype development to the production of customized medical implants. The process is particularly suitable for flexible small series that can be implemented without tooling costs.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Samples\u002Fsmall series and prototypes\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>3D printing is particularly suitable for the cost-effective production of small series, as expensive tools are not required. This is particularly advantageous for companies that need flexible and demand-driven production of construction or spare parts. In addition, 3D printing technology is ideal for producing detailed samples and models, especially in industries such as design and architecture, where realistic models are of great importance for planning and visualization.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Healthcare\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In healthcare, 3D printing enables the production of customized medical elements that can be precisely tailored to the individual characteristics of a patient. This increases the success rate of implantations and minimizes the risk of complications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industry & mechanical engineering\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:41%;\">\u003Cimg style=\"aspect-ratio:5350\u002F3568;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Frobotic_arm_modern_industrial_technology_automated_S8_LWKA_6_f46cc37745.jpg\" alt=\"Kunststoff Tiefziehteile für Industrie\" width=\"5350\" height=\"3568\">\u003C\u002Ffigure>\u003Cp>In various industries such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmechanical-engineering\">mechanical engineering\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive\u003C\u002Fa>, 3D printing is used to produce customized spare parts. This enables efficient production of components, especially for models where conventional manufacturing methods may no longer be economical.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Application areas in thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The thermoforming process has been an established production method for transport packaging, housings, covers and blisters for decades. It is characterized by high formability, low tooling costs and fast cycle times.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive industry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In the automotive sector, thermoforming is the preferred method for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">plastic trays\u003C\u002Fa>.\u003C\u002Fp>\u003Cul>\u003Cli>Use for body parts, electronic modules and vehicle components\u003C\u002Fli>\u003Cli>Complex and precisely fitting carrier systems secure transport\u003C\u002Fli>\u003Cli>Increasing efficiency along production lines\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industry & mechanical engineering\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In industrial use, thermoformed plastic parts are used for a variety of applications, including:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">Housings and covers\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Screen frames and machine parts\u003C\u002Fli>\u003Cli>Automation trays and workpiece carriers\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">Plastic tubs and containers\u003C\u002Fa> are also widespread, e.g. for chemicals, liquids, as potting molds or for transport through industrial washing systems.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Electrical and electronics industry\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed parts with \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection\u003C\u002Fa> prevent damage to sensitive electronic components.\u003C\u002Fp>\u003Cul>\u003Cli>Use in transport and storage logistics in the form of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD trays\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Use in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">electronic housings\u003C\u002Fa> and covers\u003C\u002Fli>\u003Cli>ESD protection through specific surface resistance and material selection\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Thermoforming and 3D printing - A conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In conclusion, the comparison of thermoforming and 3D printing shows that both technologies have specific strengths and weaknesses that should be considered depending on the requirements of a project or product.\u003Cbr>3D printing is primarily suitable for creating short-term prototypes and very small quantities. Thermoforming proves to be a \u003Cstrong>cost-effective\u003C\u002Fstrong> option for medium to large volumes. In addition, thermoforming offers fast production costs, comparatively low tooling costs and material efficiency, as well as broad material requirements.\u003C\u002Fp>\u003Cp>Do you have questions about thermoforming? We are happy to help. Simply \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact us\u003C\u002Fa> or subscribe to our newsletter for the latest information from the world of thermoformed parts!\u003C\u002Fp>","thermoforming-vs-3d-printing",{"id":713,"documentId":714,"createdAt":715,"updatedAt":716,"publishedAt":85,"locale":10,"title":717,"introduction":718,"content":719,"slug":720},377,"z04clvcm39kx033cnl5xscms","2026-01-13T15:51:52.763Z","2026-06-15T17:51:13.692Z","Thermoforming Tool for Plastic Thermoformed Parts: Structure, Types, and Manufacturing","Plastic thermoforming is a process in which a plastic sheet or film is heated and shaped over a mold to create various three-dimensional objects. A crucial element in the thermoforming process is the tooling used to achieve the desired shape.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Thermoforming Tools for Plastic Thermoformed Parts – Key Facts at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Thermoforming tools\u003C\u002Fstrong> are indispensable in the thermoforming process, as they precisely shape plastic sheets and films, cool them, and define the surface quality. Each tool is individually designed for the specific product.\u003C\u002Fli>\u003Cli>\u003Cstrong>Aluminum\u003C\u002Fstrong> is the standard material for durable production tools, while Ureol, 3D printing, and wood are mainly used for prototypes or small quantities to reduce costs and development time.\u003C\u002Fli>\u003Cli>\u003Cstrong>Negative and positive thermoforming tools \u003C\u002Fstrong>differ in shaping and level of detail: Negative molds allow smooth surfaces and good wall thickness distribution, while positive molds are more cost-effective but less detailed.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is a Thermoforming Tool?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>A thermoforming tool is a specialized tool used in the single-sheet or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftwin-sheet-process\">twin-sheet\u003C\u002Fa> process to shape thermoplastic sheets or films, which are produced through \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastic extrusion, \u003C\u002Fa>into molded plastic components. The material is softened by heating and then formed into a shape using \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">vacuum forming\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpneumatic-forming\">pressure forming.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1784\u002F813;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FIsometric_View_d4a648ce55.webp\" alt=\"Isometric View of a thermoforming tool\" width=\"1784\" height=\"813\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why Is a Thermoforming Tool Necessary?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoforming tools are essential for the deep-drawing process. Without a precise thermoforming tool, plastic cannot be shaped into the desired form. Each tool is custom-made for every product development, designed to meet specific requirements, and then installed in the machine for production—a process known as machine setup.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Custom Adaptation\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Since thermoforming tools are tailored for each product, they are typically unique and adapted to the specific project’s production volume, quality standards, and tolerances.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Functions of Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoforming tools serve multiple functions in the manufacturing process:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Shaping\u003C\u002Fstrong> – The tool gives the heated plastic its final shape.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling\u003C\u002Fstrong> – It facilitates cooling to stabilize the form.\u003C\u002Fli>\u003Cli>\u003Cstrong>Surface Finish\u003C\u002Fstrong> – The tool influences the texture and quality of the finished product’s surface.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:806\u002F291;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FHeating_of_the_thermoforming_tool_f40273aa2a.webp\" alt=\"Heating of the thermoforming tool\" width=\"806\" height=\"291\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Do You Need a New Thermoforming Tool for Every Product?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Yes, since thermoforming tools are custom-made for each product. However, once a tool is created, it can be used for tens or even hundreds of thousands of production cycles, especially if made from aluminum and properly maintained.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the Difference Between Single-Cavity and Multi-Cavity Tooling?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In thermoforming, a cavity refers to the representation of the product in the tool. Depending on the required quantity, the tool can be designed as a single-cavity or multi-cavity tool.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Single-Cavity Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>One cavity on the tool represents the product to be thermoformed. For small quantities, the tool can be designed with just one cavity, known as a single-cavity tool. This means that only one part is produced per cycle.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Multi-Cavity-Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>For large quantities, it is often worth creating a more cost-intensive multi-cavity tool. This means that the thermoforming tool does not contain just one shape of the thermoformed product, but several identical shapes that are produced per cycle. Each additional cavity in the tool reduces the required cycle time per part and therefore lowers the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">unit costs.\u003C\u002Fa>\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n.c-container {\nborder: 2px solid #15A9A4;\npadding: 10px;\nmargin: 10px;\nborder-radius: 10px;\n}\n\n.c-container {\nmargin: 0;\n}\n\u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n\u003Cp>ℹ️ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcase-studies\u002Fproject-with-naext\">case study with NAEXT,\u003C\u002Fa> you will learn how we were able to produce a battery housing including its corresponding cover in a single production step using a multi-cavity tool.\u003C\u002Fp>\n\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Happens to Thermoforming Tools After Use?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>After use, the tool is removed from the machine, cleaned, and inspected to ensure it is fully ready for the next application. If necessary, minor repairs or adjustments are made before the tool is stored by the thermoforming supplier.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Materials are Used to Make a Thermoforming Tool?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Thermoforming tools are usually made of aluminum. However, in addition to aluminum, there are also other, more cost-effective material options that are mainly used for prototypes or sampling and can have a positive impact on costs:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Aluminum (Industry Standard for Serial Production)\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Most commonly used due to its high precision, durability, and lightweight properties.\u003C\u002Fli>\u003Cli>Water-cooled aluminum tools allow for fast cooling times, making them ideal for high-speed production.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:19.31%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehwerkzeug_aus_Aluminium_14e5426ea7.png\" alt=\"Tiefziehwerkzeug aus Aluminium\">\u003Cfigcaption>Aluminum deep drawing tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Ureol (Polyurethane Foam)\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Used for prototypes due to its low cost and easy machining.\u003C\u002Fli>\u003Cli>Not as durable as aluminum and suitable only for limited production runs.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:19.83%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehwerkzeug_aus_Ureol_774b94170a.png\" alt=\"Tiefziehwerkzeug aus Ureol\">\u003Cfigcaption>Deep-drawing tool made of ureol\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D-Printed Plastic\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Fast and cost-effective for prototyping and testing.\u003C\u002Fli>\u003Cli>Only capable of producing a small number of samples due to heat resistance limitations.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:18.67%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_gedrucktes_Tiefziehwerkzeug_211216daea.png\" alt=\"3D-gedrucktes Tiefziehwerkzeug\">\u003Cfigcaption>3D-printed thermoforming tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Wood\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Rarely used, as it wears out quickly and lacks precision.\u003C\u002Fli>\u003Cli>Can be utilized for simple forming stamps or pre-stretching components.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Construction of Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The thermoforming tool consists of several components, including the mold itself, cooling channels that ensure uniform cooling, and holding devices that keep the plastic in position during the process. These elements work together during deep drawing to ensure precise and efficient shaping.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n.c-container {\nborder: 2px solid #15A9A4;\npadding: 10px;\nmargin: 10px;\nborder-radius: 10px;\n}\n\n.c-container {\nmargin: 0;\n}\n\u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n\u003Cp>\u003C\u002Fp>\u003Ch4>ℹ️ The mandatory tool set for deep drawing tools\u003C\u002Fh4>\nThe simplest tool set always consists of a base, a segment carrier plate and a forming tool mounted on it.\n\u003Cul>\n\u003Cli>\u003Cb>Forming tool:\u003C\u002Fb> The forming body of the deep drawing tool.\n\u003C\u002Fli>\u003Cli>\u003Cb>Segment carrier plate:\u003C\u002Fb> The carrier plate for the forming tool.\n\u003C\u002Fli>\u003Cli>\u003Cb>Base:\u003C\u002Fb> The segment carrier plate with the forming tool is screwed onto this. The base is the interface to the machine. Each machine requires an individual base, which is usually the same for certain models depending on the manufacturer.\n\u003C\u002Fli>\u003C\u002Ful>\n\u003Cp>\u003C\u002Fp>\n\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Cp>The aim is to keep the deep-drawing tool within a constant temperature range in order to achieve a uniform result.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:919\u002F862;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStructure_of_a_thermoforming_tool_ad9adef5d8.webp\" alt=\"Structure of a thermoforming tool\" width=\"919\" height=\"862\">\u003C\u002Ffigure>\u003Cp>The illustration shows a cross-section of the entire structure of a tool, including some standard tool components. Shown here are the machine base (8) and the carrier plate (7 in petrol), on which the positive mold (13) is mounted, which works with compressed air (1) and vacuum (9). The material (5), i.e. the plastic roll or sheet, is marked in black here.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Additional Components of Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In addition to the mandatory tool set (which of course also varies from machine to machine), further tool components can be created. Each of these components fulfills a specific purpose. When designing the deep-drawing tool, a decision is made as to whether and in what form separate components need to be created.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Optical and Mechanical Requirements\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>This depends primarily on the optical and mechanical requirements of the deep-drawn part. In some cases, additional components are used “only” to optimize the result, while in others, additional components are essential for a functional part. It is important to consider the tool options available.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Pre-stretching punch\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The pre-stretching punch, also known as the upper punch, is used to pre-stretch and shape the material in order to achieve better forming sharpness. Pre-stretching distributes the material more evenly, which allows for deep, complex shapes and the use of thinner starting thicknesses.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:959\u002F887;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCross_section_of_an_upper_punch_thermoforming_tool_e047f0f55f.webp\" alt=\"Cross section of an upper punch thermoforming tool\" width=\"959\" height=\"887\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Spanning frame components\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Spanning frames clamp the material during \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fplattenfertigung\">deep-drawing from the plastic sheet\u003C\u002Fa> during processing to hold it in place during forming.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1835\u002F822;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSegment_carrier_plate_d1b0fdd747.webp\" alt=\"Segment carrier plate\" width=\"1835\" height=\"822\">\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ejectors\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Automated ejectors support demolding. These are used to achieve faster cycle times and to automatically feed the deep-drawn parts to a stacking unit.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Stacking stations\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>After the deep-drawn part has been removed from the deep-drawing tool, stacking stations can automatically stack the parts into stacking units. This facilitates the removal and packaging process from the machine.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the Difference Between Positive and Negative Tools in Thermoforming?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Basically, during the forming process, the semi-finished product is stretched into the desired shape by placing the heated material in a rubber-elastic form on the tool and allowing it to cool.\u003C\u002Fp>\u003Cp>The forming process can be divided into two types: positive and negative molding. The choice of process depends primarily on which side of the deep-drawn part must be dimensionally accurate and whether the required stability must be maintained at the bottom or at the edge of the plastic deep-drawn part.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Negative Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In negative molding, the semi-finished product is pressed into the concave mold cavity. This can be done using vacuum or additional compressed air. To ensure uniform wall thicknesses, an upper punch made of an insulating material can also be used, which pushes material into thinning areas of the deep-drawn part during molding.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:858\u002F768;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FNegativ_Tiefziehwerkzeug_21b50ae2bf.png\" alt=\"Negativ-Tiefziehwerkzeug\" width=\"858\" height=\"768\">\u003Cfigcaption>Negative deep-drawing tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages and Disadvantages of Negative Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of negative deep-drawing tools\u003C\u002Fth>\u003Cth>Disadvantages of negative deep-drawing tools\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Good wall thickness distribution\u003C\u002Ftd>\u003Ctd>Increased material costs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Smooth, flawless surface\u003C\u002Ftd>\u003Ctd>Increased risk of material cracks and wrinkling\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Good demoldability \u003C\u002Ftd>\u003Ctd>Top punch usually required\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Positive Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In positive molding, the semi-finished product is pulled over a \u003Cstrong>convex elevation\u003C\u002Fstrong>. To avoid thin spots at the edges, the material is often pre-blown with compressed air from below.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:910\u002F830;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPositiv_Tiefziehwerkzeug_95cf66e92e.png\" alt=\"Positiv-Tiefziehwerkzeug\" width=\"910\" height=\"830\">\u003Cfigcaption>Positive deep-drawing tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages and Disadvantages of Positive Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of positive deep-drawing tools\u003C\u002Fth>\u003Cth>Disadvantages of positive deep-drawing tools\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Simple and cost-effective production\u003C\u002Ftd>\u003Ctd>Lower level of detail\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Improved wall thickness distribution compared to negative tools without upper punch \u003C\u002Ftd>\u003Ctd>Limited surface quality, the outside of the part may be less smooth, which affects aesthetics\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Good surfaces on the outside \u003C\u002Ftd>\u003Ctd>Difficult demolding with complex geometries\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Manufacturing of Thermoforming Tools\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Deep-drawing tools for plastics processing are manufactured in the following steps:\u003C\u002Fp>\u003Col>\u003Cli>Design\u003C\u002Fli>\u003Cli>CNC milling\u003C\u002Fli>\u003Cli>Manual re-milling\u003C\u002Fli>\u003C\u002Fol>\u003Cp>More on this in the following sections.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Designing the Thermoforming Tool\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The first step in the manufacture of a deep-drawing tool is the design, which is usually done using \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fconstruction-data-in-thermoforming\">CAD data\u003C\u002Fa> that shows the deep-drawing tool sketch. The exact specifications and designs of the tool are developed to ensure that the thermoforming tool meets the requirements. \u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">CNC Milling\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>After design, the deep drawing tool is machined from the selected material using 5-axis \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Ftrennen\u002Fcnc-milling\">CNC milling.\u003C\u002Fa> CNC milling offers high precision, which is essential for the manufacture of high-quality tools.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:768\u002F454;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCNC_Fraesen_von_Tiefziehwerkzeugen_11f4f4139c.jpg\" alt=\"CNC-Fräsen von Tiefziehwerkzeugen\" width=\"768\" height=\"454\">\u003C\u002Ffigure>\u003Ch3>Manual Re-milling\u003C\u002Fh3>\u003Cp>CNC milling is often followed by manual reworking to optimize fine details, create very precise vacuum holes, and improve the surface quality. These reworking steps are essential to ensure that the deep-drawing tool meets the high requirements of production.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Deep-drawing tools in plastic thermoforming – a conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Deep-drawing tools are essential for the production of plastic deep-drawn parts. When designing the tool, it is important to consider which additional components are required to meet the requirements of the deep-drawn part in order to meet the quality standards. The optimal deep-drawn part is therefore designed to suit the material, process, and tool.\u003C\u002Fp>\u003Cp>Would you like to get started with your deep drawing project and have further questions about deep drawing tools? Then read our\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fdesign-guide\"> design guide,\u003C\u002Fa> which answers all your questions about thermoforming.\u003C\u002Fp>","tools-for-thermoformed-plastic-parts",{"id":722,"documentId":723,"createdAt":724,"updatedAt":725,"publishedAt":85,"locale":10,"title":726,"introduction":727,"content":728,"slug":729},350,"m8zzptx9l09znjfx044u28ia","2026-01-13T15:51:47.618Z","2026-05-29T18:09:51.749Z","Cleaning Trays: This is how to clean reusable trays","Workpiece carriers transport components in various stages of production and are used for long periods. Many components, especially in the automotive industry, are oily or greasy, and during transport, dirt and other contaminants accumulate. Therefore, it is important to clean the trays.","\u003Ch2>Cleaning trays - Key points at a glance\u003C\u002Fh2>\u003Cul>\u003Cli>The \u003Cstrong>design\u003C\u002Fstrong> and \u003Cstrong>material selection\u003C\u002Fstrong> of plastic trays should consider the cleaning process from the start.\u003C\u002Fli>\u003Cli>Industrial cleaning processes expose trays to \u003Cstrong>high stresses\u003C\u002Fstrong> such as heat, chemicals, and water pressure.\u003C\u002Fli>\u003Cli>The right material selection, robust construction, and involvement of cleaning experts are crucial for a long service life of the trays.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>, you can add drainage holes to the tray to optimally equip it for washing processes.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does tray cleaning affect design?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The cleaning of used \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">plastic trays\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-a-workpiece-carrier\">workpiece carriers\u003C\u002Fa> usually takes place at the end of the production chain or is even completely separated from the production process and carried out by external service providers. Trays are usually designed with a focus on the production process they are intended to optimize. \u003C\u002Fp>\u003Cp>Nevertheless, it is important to consider tray cleaning right from the start of development. That's why you can specify washing processes in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa> when you make your inquiry.\u003C\u002Fp>\u003Ch2>How is a tray cleaned industrially?\u003C\u002Fh2>\u003Cp>Usually, production sites sort out trays that need to be cleaned and place them at a collection point where they are picked up for workpiece carrier cleaning. The cleaning of the trays then takes place either in-house or at an external service provider. \u003Cstrong>Industrial washing systems\u003C\u002Fstrong> are used for this purpose.\u003C\u002Fp>\u003Cfigure class=\"image image-style-side\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fwarentransport_waschbaerkeit_01_313e19297d.png\" alt=\"warentransport-waschbaerkeit-01.png\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Ch3>The cleaning process in the washing system\u003C\u002Fh3>\u003Cp>The designs of washing systems are as diverse as the cleaned articles, workpiece carriers and components. In simplified terms, the washing process usually includes the following steps:\u003C\u002Fp>\u003Col>\u003Cli>Pre-sorting\u003C\u002Fli>\u003Cli>Removal of foreign objects (e.g. labels)\u003C\u002Fli>\u003Cli>Multi-stage washing process according to requirements, e.g.:\u003Cul>\u003Cli>Pre-wash zone\u003C\u002Fli>\u003Cli>Ultrasonic\u003C\u002Fli>\u003Cli>Spraying\u003C\u002Fli>\u003Cli>Immersion degreasing\u003C\u002Fli>\u003Cli>Injection flood washing\u003C\u002Fli>\u003Cli>High-pressure water jet technology\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003Cli>Drying process\u003C\u002Fli>\u003C\u002Fol>\u003Cp>The latter is particularly important for \u003Cstrong>delicate electronic components\u003C\u002Fstrong> where residual moisture can quickly lead to corrosion. After the professional cleaning process, the reusable workpiece carriers can be immediately returned to the production cycle.\u003C\u002Fp>\u003Ch2>What does the tray have to withstand during cleaning?\u003C\u002Fh2>\u003Cp>During industrial cleaning, trays are exposed to particular stresses. The choice of the right material and design must withstand these influences. Here are the most important factors:\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2173\u002F724;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGraphic_washing_Tray_resistances_83850bb06a.webp\" alt=\"Graphic washing Tray resistances\" width=\"2173\" height=\"724\">\u003Cfigcaption>Effects on the tray during the washing process\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cul>\u003Cli>\u003Cstrong>Solvents and chemicals:\u003C\u002Fstrong> These are used to remove grease, oils or paints and can have an aggressive effect on the tray surface.\u003C\u002Fli>\u003Cli>\u003Cstrong>Mechanical high pressure:\u003C\u002Fstrong> Water jets can damage delicate contours.\u003C\u002Fli>\u003Cli>\u003Cstrong>High temperatures:\u003C\u002Fstrong> Drying processes, as is common in industrial cleaning, expose the material to high temperatures.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>What cleaning techniques are available?\u003C\u002Fh3>\u003Cp>In addition to standard washing processes, there are gentler techniques such as ultrasonic cleaning.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Ultrasonic cleaning:\u003C\u002Fstrong> In this method, the workpiece carrier is immersed in a bath that is set into vibrations by sound waves. This creates tiny bubbles that, when they burst, loosen the dirt from the surface. Aggressive chemicals can often be avoided this way.\u003C\u002Fli>\u003Cli>\u003Cstrong>Drying:\u003C\u002Fstrong> Drying can be done via \u003Cstrong>vacuum technology\u003C\u002Fstrong>. Drying processes for sensitive components are carried out using warm air circulation systems or contactless, antistatic air purifiers. The possibilities are diverse.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>How your tray can survive many washing processes unharmed during cleaning\u003C\u002Fh2>\u003Cp>Since we have already designed many thermoformed trays and workpiece carriers that are suitable for industrial cleaning systems, we can tell you what matters.\u003C\u002Fp>\u003Ch3>1.) The right material selection\u003C\u002Fh3>\u003Cp>For reusable containers, thicker material gauges are generally used to make the tray stable for months or years of use.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_in_Haenden_873bd6b3b2.webp\" alt=\"Kunststoffgranulat in den Händen\">\u003Cbr>Important properties include:\u003C\u002Fp>\u003Cul>\u003Cli>Impact strength\u003C\u002Fli>\u003Cli>Hardness\u003C\u002Fli>\u003Cli>Resistance to chemicals and solvents\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Only \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> that are \u003Cstrong>not reactive\u003C\u002Fstrong> with the cleaning agents used are suitable. Although high-quality plastics are initially more expensive, they quickly pay for themselves through \u003Cstrong>longer service life, stability and consistent quality\u003C\u002Fstrong>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:45.88%;\">\u003Cimg style=\"aspect-ratio:312\u002F312;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFormnester_von_Kunststofftrays_b2f1c00a99.svg\" alt=\"Formnester von Kunststofftrays\" width=\"312\" height=\"312\">\u003C\u002Ffigure>\u003Ch3>2.) Design must-dos for cleaning-resistant trays\u003C\u002Fh3>\u003Cp>The design should be adapted to the \u003Cstrong>environmental influences of cleaning\u003C\u002Fstrong>:\u003C\u002Fp>\u003Cul>\u003Cli>Reinforcements at heavily stressed areas\u003C\u002Fli>\u003Cli>no thin spots in cavities\u003C\u002Fli>\u003Cli>more complex tool designs for longer durability\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Additional features facilitate cleaning:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>water-repellent edges\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>\u003Cstrong>drainage holes\u003C\u002Fstrong> in cavities and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fhow-to-determine-tray-cavities\">form nests\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>3.) Involve cleaning service providers early\u003C\u002Fh3>\u003Cp>The design is most efficient when the internal or external cleaning service provider is involved from the start. To avoid unwanted chemical reactions, two approaches can be taken:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Starting from the cleaning agent:\u003C\u002Fstrong> Service provider names the planned agent, formary checks plastic compatibility.\u003C\u002Fli>\u003Cli>\u003Cstrong>Starting from the plastic:\u003C\u002Fstrong> formary recommends suitable agents that the service provider validates with their system.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This way, unwanted reactions can be avoided and the tray can be optimally prepared for \u003Cstrong>reusable application\u003C\u002Fstrong>.\u003C\u002Fp>\u003Chr>\u003Ch2>Conclusion: Cleaning begins at the tray design stage\u003C\u002Fh2>\u003Cp>For plastic trays to reliably survive many industrial washing processes, cleaning should not only be considered at the end of the production process. It is crucial that material selection, wall thicknesses, geometry and additional features such as drainage holes are already adapted during design to the subsequent stress from chemicals, temperature, water pressure and drying.\u003C\u002Fp>\u003Cp>This early planning particularly pays off for reusable trays: the tray remains stable longer, cleaning quality is improved and failures in the production cycle can be avoided.\u003C\u002Fp>","how-to-clean-trays",{"id":731,"documentId":732,"createdAt":733,"updatedAt":734,"publishedAt":85,"locale":10,"title":735,"introduction":736,"content":737,"slug":738},357,"p7sxm92yi6m2pzgb2lfq57xu","2026-01-13T15:51:49.000Z","2026-06-02T16:36:59.283Z","Twin-Sheet Process: Definition, Advantages, and Applications","The Twin-Sheet process is a thermoforming technique that differs from the Single-Sheet process. In this method, two plastic sheets are heated and shaped simultaneously, enabling the production of hollow and stable components with complex geometries.","\u003Ch2>\u003Cspan style=\"color:#005250;\">The Twin-Sheet Process – Key Points at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>In the \u003Cstrong>twin-sheet process\u003C\u002Fstrong>, two plastic sheets are heated, shaped and welded simultaneously, resulting in sturdy, hollow components with a double-walled structure.\u003C\u002Fli>\u003Cli>The process offers \u003Cstrong>numerous advantages\u003C\u002Fstrong>, such as high strength combined with low weight, precise shaping, cost-effectiveness, a wide range of materials, and the ability to produce large components or inserts.\u003C\u002Fli>\u003Cli>Twin-sheet thermoforming is primarily used in the automotive industry, the packaging industry, medical technology, and for consumer goods such as sports and leisure equipment.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">→ Enquire now about thermoformed parts using the twin-sheet process\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the twin-sheet process?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The twin-sheet process, also known as twin-sheet thermoforming, is a further development of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Ftiefziehen-kunststoff\">plastic thermoforming,\u003C\u002Fa> which is also known as the \u003Cstrong>single- or mono-sheet process\u003C\u002Fstrong>. Whereas in conventional thermoforming a single \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fplattenfertigung\">plastic sheet\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Frollenfertigung\">roll\u003C\u002Fa> is formed, in the twin-sheet process two plastic sheets are processed simultaneously to produce a hollow component.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ Find out more about the differences between single-sheet thermoforming and twin-sheet thermoforming in this\u003Ca href=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=2_KRmNsF1Gw&t=49s\"> video. \u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">European vs. American version\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>European version:\u003C\u002Fstrong> Both plates are \u003Cstrong>formed at the same time\u003C\u002Fstrong>.\u003C\u002Fli>\u003Cli>\u003Cstrong>US version:\u003C\u002Fstrong> The plates are shaped \u003Cstrong>one after the other\u003C\u002Fstrong> and then joined together.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Process steps in twin-sheet thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A crucial step is \u003Cstrong>negative deep drawing\u003C\u002Fstrong>:\u003C\u002Fp>\u003Col>\u003Cli>Both plastic sheets are heated to the \u003Cstrong>thermoplastic range\u003C\u002Fstrong>.\u003C\u002Fli>\u003Cli>The \u003Cstrong>shaping and welding\u003C\u002Fstrong> are carried out in a single operation.\u003C\u002Fli>\u003Cli>The bond is formed solely by \u003Cstrong>temperature and pressure\u003C\u002Fstrong>, without the use of any additional adhesives.\u003C\u002Fli>\u003C\u002Fol>\u003Cp>The result is a high-strength, stress-free joint that offers flexible design options and excellent stability.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Single-Sheet vs. Twin-Sheet-Thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Criterion\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Single-Sheet (classic thermoforming)\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Twin-Sheet (advanced thermoforming)\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Material usage\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>One plastic sheet or film\u003C\u002Ftd>\u003Ctd>Two plastic sheets simultaneously\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Stability\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Stability depends on material thickness\u003C\u002Ftd>\u003Ctd>Very high stability through welded double structure\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Process steps\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Heating and forming one sheet\u003C\u002Ftd>\u003Ctd>Simultaneous heating, forming and welding of both sheets\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Connection\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>None, component remains single-layer\u003C\u002Ftd>\u003Ctd>Solid, stress-free connection through heat and pressure\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Design possibilities\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Limited due to single-sided forming\u003C\u002Ftd>\u003Ctd>Very flexible, complex geometries also possible\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Typical applications\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Packaging, blisters, covers, inlays\u003C\u002Ftd>\u003Ctd>Hollow bodies, tanks, technical housings, double-wall parts\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does the twin-sheet process work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The twin-sheet process consists of several steps and can be divided into the following process:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Material selection\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Two plastic sheets are clamped into the thermoforming machine. The sheets can be made of identical or different \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">\u003Cspan style=\"color:#005250;\">materials\u003C\u002Fspan>\u003C\u002Fa>, depending on the desired properties of the end product, such as strength, UV resistance, or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">\u003Cspan style=\"color:#005250;\">ESD protection\u003C\u002Fspan>\u003C\u002Fa>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fesd-trays-aus-kunststoff-einsatz-und-vorteile\">.\u003C\u002Fa> This allows for a high degree of flexibility in the design of the thermoformed parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Heating\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:15.93%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTwin_Sheet_Verfahren_Schritt_1_0ed40429c1.png\" alt=\"Twin-Sheet-Verfahren: Erhitzung\">\u003Cfigcaption>Twin-sheet process: Heating\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>In the twin-sheet process, both plastic sheets are heated simultaneously until they reach the so-called thermoelastic state, in which they are soft and malleable. It is important that the heating is uniform in order to avoid material stresses and guarantee high-quality shaping. This step is typically carried out in special ovens that are integrated into the thermoforming machine.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Shaping\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.17%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTwin_Sheet_Verfahren_Formgebung_542af96377.png\" alt=\"Twin-Sheet-Verfahren: Formgebung\">\u003Cfigcaption>Twin-sheet process: shaping\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>Once the plastic rolls or sheets have reached the right temperature, they are placed in two separate halves of a mold. Each sheet is pressed into its own cavity, where it is drawn into the desired shape using \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">\u003Cspan style=\"color:#005250;\">vacuum\u003C\u002Fspan>\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpneumatic-forming\">\u003Cspan style=\"color:#005250;\">compressed air\u003C\u002Fspan>\u003C\u002Fa>. This process enables precise shaping and ensures that even complex geometries can be reliably produced.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Welding\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:15.47%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTwin_Sheet_Verfahren_Verschweissung_9c69b46d92.png\" alt=\"Twin-Sheet-Verfahren Verschweißung\">\u003Cfigcaption>Twin-sheet process: Welding\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>While the sheets are still warm and malleable, the two mold halves are pressed together so that the plastic sheets fuse together at the points of contact. This results in a permanent and stable bond that forms a hollow structure. The double wall thickness creates a component with particularly high strength that meets the requirements for structural load-bearing capacity.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Cooling and removal of the component\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:16.17%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTwin_Sheet_Verfahren_Entnahme_a9426c60c8.png\" alt=\"Twin-Sheet-Verfahren: Abkühlung und Entnahme\">\u003Cfigcaption>Twin-sheet process: cooling and removal\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>Once the molded component has cooled, it is removed from the mold and can be used for further processing or direct use.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the advantages of the twin-sheet process?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The twin-sheet process offers several significant advantages over other plastic processing methods:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Increased stability:\u003C\u002Fstrong> Twin-sheet thermoforming is characterized by high structural strength, which is achieved by the double wall structure of the components. This not only ensures high stability, but also enables weight reduction, as stable and rigid parts can be produced with less material.\u003C\u002Fli>\u003Cli>\u003Cstrong>High accuracy\u003C\u002Fstrong>: Both sides of the molded parts benefit from double-sided mold contact, which increases accuracy. This is reflected in the visually appealing quality of both sides of the component.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cost-effectiveness\u003C\u002Fstrong>: Compared to conventional processes such as blow molding or injection molding, the cost of the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">\u003Cspan style=\"color:#005250;\">deep-drawing tool\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:#005250;\"> \u003C\u002Fspan>is often more cost-effective with the twin-sheet process. This is because two sheets are processed simultaneously, which reduces the need for additional processing steps and tools.\u003C\u002Fli>\u003Cli>\u003Cstrong>Large part dimensions\u003C\u002Fstrong>: The process enables the production of very large parts at relatively low tool and part prices, which further increases cost-effectiveness.\u003C\u002Fli>\u003Cli>\u003Cstrong>Inserts and insert parts\u003C\u002Fstrong>: The twin-sheet process allows inserts to be inserted directly into the cavity of the component. This means that complex shapes and integrated functional elements such as reinforcements or mounting points can be easily integrated into the component.\u003C\u002Fli>\u003Cli>\u003Cstrong>Material diversity\u003C\u002Fstrong>: It is possible to combine different materials and colors on the inside and outside of the parts. A mix of new and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-recyclate\">\u003Cspan style=\"color:#005250;\">recycled\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:#005250;\"> \u003C\u002Fspan>materials is also possible.\u003C\u002Fli>\u003Cli>\u003Cstrong>Fast implementation times\u003C\u002Fstrong>: Even larger components can be produced quickly, which shortens production times.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">In which industries is the twin-sheet process used?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The twin-sheet process is characterized by its versatility and is of great interest in numerous industries.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">\u003Cspan style=\"color:#005250;\">automotive\u003C\u002Fspan>\u003C\u002Fa> sector, twin-sheet thermoforming is often used to manufacture air ducts, door panels, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">\u003Cspan style=\"color:#005250;\">covers\u003C\u002Fspan>\u003C\u002Fa> for luggage compartments, and other interior trim. These applications benefit from the high strength and ability to efficiently produce complex geometries.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:53.3%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Flenny_kuhne_j_HZ_70n_Rk7_Ns_unsplash_69c025e3ea.jpg\" alt=\"Automotive-Branche\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Packaging\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Another key sector is the packaging industry, where the twin-sheet process is used to produce sturdy, reusable \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">thermoformed containers\u003C\u002Fa> and pallets. These are used, for example, as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">food packaging\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">ESD packaging\u003C\u002Fa> and many other packaging solutions.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Medical technology\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">\u003Cspan style=\"color:#005250;\">medicine\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:#005250;\">,\u003C\u002Fspan> the process is used in the manufacture of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">\u003Cspan style=\"color:#005250;\">medical technology housings\u003C\u002Fspan>\u003C\u002Fa>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fprodukte\u002Fmedizintechnik-gehaeuse-aus-kunststoff\">,\u003C\u002Fa> which must be both lightweight and robust.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:69.81%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fnational_cancer_institute_o_C_Lu_Fi9_GYNA_unsplash_0380e3eabd.jpg\" alt=\"Medizinbranche\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Consumer goods\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The process also plays a central role in the manufacture of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fthermoformed-plastic-packaging\">\u003Cspan style=\"color:#005250;\">consumer goods\u003C\u002Fspan>\u003C\u002Fa> such as leisure and sports equipment. For example, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fcaravan-covers\">\u003Cspan style=\"color:#005250;\">caravan covers\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:#005250;\">,\u003C\u002Fspan> kayaks, and other leisure equipment are produced using the twin-sheet process, enabling manufacturers to create high-performance yet lightweight products.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Twin-sheet thermoforming – a summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The twin-sheet process is a \u003Cstrong>powerful and flexible technology\u003C\u002Fstrong> that offers numerous advantages in both mass production and special applications. Thanks to its ability to combine complex geometries with high structural strength and low weight, twin-sheet thermoforming is used in a wide range of industries.\u003C\u002Fp>\u003Cp>Would you like to know whether single-sheet thermoforming or the twin-sheet process is more suitable for your application? Then \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">\u003Cspan style=\"color:#005250;\">\u003Cstrong>contact\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fa> us and we will be happy to help you.\u003C\u002Fp>","twin-sheet-process",{"id":740,"documentId":741,"createdAt":742,"updatedAt":743,"publishedAt":85,"locale":10,"title":744,"introduction":745,"content":746,"slug":747},339,"gn79sl32j0pu31hzm2ugo6lw","2026-01-13T15:51:45.558Z","2026-06-02T16:58:54.482Z","Comparison: Plastic vs. Metal – Differences, Similarities, Advantages & Disadvantages","Metals and plastics are two essential material categories used across various industries and applications, from consumer goods manufacturing to the production of technical components.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic vs. Metal – The Key Points at a Glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Properties:\u003C\u002Fstrong> Metals offer high strength and heat resistance. Plastics are attractive due to their lower weight, corrosion resistance and design flexibility.\u003C\u002Fli>\u003Cli>\u003Cstrong>Manufacturing:\u003C\u002Fstrong> The processing of plastics is generally more cost-effective and energy-efficient than that of metals.\u003C\u002Fli>\u003Cli>\u003Cstrong>Areas of application:\u003C\u002Fstrong> Metals are predominant in the aerospace and mechanical engineering sectors. Plastics have become indispensable in the automotive industry, as well as in the manufacture of casings and packaging.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Structure and composition of plastics and metals\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>A comparison of the structure and composition of the two materials, plastic and metal: \u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Metals – Structure and Properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Metals have a long history in various industries, including\u003C\u002Fspan> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive manufacturing, \u003C\u002Fa>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmechanical-engineering\">mechanical engineering \u003C\u002Fa>and energy generation. These industries shaped the Industrial Revolution, when metal became the standard material of choice. \u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Advantages of metals\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Strength\u003C\u002Fli>\u003Cli>heat resistance\u003C\u002Fli>\u003Cli>Aesthetics\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">The structure of metals\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Metals consist of \u003Cstrong>metallic elements\u003C\u002Fstrong> with a crystalline structure. The atoms are arranged in a \u003Cstrong>regular lattice\u003C\u002Fstrong>, which gives them high strength, density and electrical conductivity.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStruktur_von_Werkstoffen_Vergleich_Kunststoff_und_Metall_f8fcfb5b28.jpg\" alt=\"Struktur von Werkstoffen Vergleich Kunststoff und Metall\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics – Structure and Properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The development and use of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> began in the 19th century, but their rise to become a widely used and important material across various industries did not begin until the 1950s. Since then, they have been regarded as a \u003Cstrong>cost-effective alternative\u003C\u002Fstrong> to metal, glass or wood, particularly in construction, the automotive industry, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fthermoformed-plastic-packaging\">packaging\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics.\u003C\u002Fa>\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Advantages of plastics\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>High ductility\u003C\u002Fli>\u003Cli>Lightness\u003C\u002Fli>\u003Cli>Electrical insulation properties\u003C\u002Fli>\u003Cli>Corrosion resistance\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">The structure of plastics\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Plastics consist of long chains of molecules known as polymers. These chains can have linear, branched or cross-linked structures. When heated, these polymers are highly malleable and can be moulded into almost any desired shape. Once they have cooled and solidified, the long chains of molecules bond together, giving the plastic its strength.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> \u003C\u002Fp>\u003Ch5>ℹ️ Why are plastics lighter than metals?\u003C\u002Fh5>The lower density of the polymers that make up plastics means that they are generally lighter than metals.\u003Cp>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch4>\u003Cspan style=\"color:#005250;\">Thermoplastics and thermosets\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>There are \u003Cstrong>two main types\u003C\u002Fstrong> of plastics:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Thermosets:\u003C\u002Fstrong> Thermosets can only be moulded into a specific shape once.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoplastics:\u003C\u002Fstrong> Thermoplastics can be reshaped several times within certain limits. This property makes \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic deep-drawing\u003C\u002Fa> possible, a process in which \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">plastic sheets\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">rolls\u003C\u002Fa> are shaped into a different form using pressure and heat.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the properties of plastic compared to metal?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Metals and plastics possess a range of properties that make them suitable for numerous applications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Flexibility and malleability – a boon for plastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The malleability of materials is important for many applications for a number of reasons. These include design flexibility in product design, manufacturability in mass production, and the possibility of repairs and maintenance.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Plastics:\u003C\u002Fstrong> can be easily heated and moulded into almost any desired shape using processes such as deep drawing, blow moulding or injection moulding. This allows for great design freedom whilst using minimal energy.\u003C\u002Fli>\u003Cli>\u003Cstrong>Metals:\u003C\u002Fstrong> are shaped by casting, bending, pressing, machining or welding. These processes are more labour-intensive, more energy-intensive and place greater restrictions on design options.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Plastics are generally \u003Cstrong>more flexible and adaptable\u003C\u002Fstrong>, whereas metals require more energy and time to be shaped.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Strength and durability – a win for metal\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In principle, components made from different materials should be able to withstand the stresses to which they are subjected, and should offer the best possible durability and efficiency.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Plastics:\u003C\u002Fstrong> can exhibit mechanical properties such as impact resistance, rigidity or flexibility. However, they are generally more susceptible to \u003Cstrong>scratches and wear and tear\u003C\u002Fstrong>.\u003C\u002Fli>\u003Cli>\u003Cstrong>Metals:\u003C\u002Fstrong> offer high strength, hardness and ductility. They can bear heavy loads, withstand temperatures of up to \u003Cstrong>500 °C\u003C\u002Fstrong> and are ideal for applications requiring high durability, such as in the construction, automotive and aerospace industries.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Plastics are highly adaptable, but metals remain the first choice for \u003Cstrong>extreme loads and a long service life\u003C\u002Fstrong>.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of plastics compared to metal\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>So why has plastic replaced metal as a material in so many applications over the last few decades? In these respects, plastics offer numerous advantages over metals:\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:29.63%;\">\u003Cimg style=\"aspect-ratio:960\u002F1044;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTuerkise_Hand_ueber_der_sich_Pluszeichen_befinden_23477ff51e.jpg\" alt=\"Türkise Hand, über der sich Pluszeichen befinden\" width=\"960\" height=\"1044\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Shock-absorbing properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In general, plastics offer better shock absorption than metals, making them ideal for shock-absorbing applications such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fprotective-covers-for-cnc-parts\">protective covers\u003C\u002Fa>, bumpers, protective sleeves and packaging materials.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sound insulation\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastics offer improved sound-insulating properties compared to metals and can therefore play an effective role in reducing noise in buildings, vehicles and machinery, such as in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmachine-covers\">machine covers\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftractor-covers\">tractor fairings\u003C\u002Fa>.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Chemical and corrosion resistance\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Compared to metals, plastics are more resistant to many corrosive environments. They generally do not react with water, acids or alkalis, making them ideal for use in damp environments and in chemical processes.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Electrical insulation properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastics offer good electrical insulation properties. Examples of their use include \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD workpiece carriers,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">ESD transport packaging\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">plastic enclosures for electronics.\u003C\u002Fa> In general, metals have very poor electrical insulation properties compared to non-conductive materials such as plastics. Metals conduct electrical current, which is why they are not suitable for use as shielding in the form of enclosures.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Thermal insulation properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastics can be good thermal insulators, particularly when compared to metals. The thermal conductivity of plastics is generally significantly lower than that of metals, which means they conduct heat more slowly through their mass. This makes plastics effective thermal insulators in many applications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Costs\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:31.33%;\">\u003Cimg style=\"aspect-ratio:500\u002F500;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FHand_die_Geld_haelt_b436b97674.png\" alt=\"Hand, die Geld hält\" width=\"500\" height=\"500\">\u003C\u002Ffigure>\u003Cp>Plastics are often less expensive than metals, both in terms of material costs and manufacturing costs.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Why metals are more expensive \u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Metals are produced through complex processes: they are made by smelting and shaping metal ores, followed by various processing methods such as casting, forging and rolling.\u003C\u002Fp>\u003Cp>These processes often require high temperatures, significant energy consumption and specialised equipment, which increases production costs compared to plastics.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Cost advantages of plastics\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Plastics can be produced in large quantities at relatively low cost. Their \u003Cstrong>weight reduction\u003C\u002Fstrong> offers additional benefits:\u003C\u002Fp>\u003Cul>\u003Cli>lower transport costs\u003C\u002Fli>\u003Cli>lower storage costs\u003C\u002Fli>\u003Cli>lower energy consumption in moving machine components\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Environmental impact and recycling\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Although plastic and metal are recyclable, the recycling of metals requires the use of high temperatures and therefore\u003Cstrong> \u003C\u002Fstrong>a very high energy input. In contrast, plastic can be shredded and reused as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-recyclate\">recycled material\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_die_sich_in_den_Haenden_befinden_66b91b7e44.png\" alt=\"Kunststoffflakes, die sich in den Händen befinden\" width=\"1920\" height=\"1080\">\u003Cfigcaption>Recycled plastic\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Comarison table of plastic and metal\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Features\u003C\u002Fth>\u003Cth>Metals\u003C\u002Fth>\u003Cth>Plastics\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Structure\u003C\u002Ftd>\u003Ctd>Crystal\u003C\u002Ftd>\u003Ctd>Polymer (linear, branched or cross-linked structure)\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cost of production\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Low\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Energy consumption\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Low\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Design options\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Durability\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Corrosion resistance\u003C\u002Ftd>\u003Ctd>Vulnerable\u003C\u002Ftd>\u003Ctd>Consistent\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Strength\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Stiffness\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Ductility\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Variable\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Weight\u003C\u002Ftd>\u003Ctd>Difficult\u003C\u002Ftd>\u003Ctd>Light\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Electrical conductivity\u003C\u002Ftd>\u003Ctd>Senior\u003C\u002Ftd>\u003Ctd>Electrical insulator\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Heat resistance\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Thermal conductivity\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003Ctd>Low to medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Thermal insulation\u003C\u002Ftd>\u003Ctd>Low\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Manufacturing process\u003C\u002Ftd>\u003Ctd>Melting, casting, forging, rolling\u003C\u002Ftd>\u003Ctd>Polymerisation, injection moulding, extrusion, thermoforming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Environmental impact\u003C\u002Ftd>\u003Ctd>Extraction and processing require energy and can cause environmental damage\u003C\u002Ftd>\u003Ctd>Plastics can be reprocessed as recycled material, but they are not biodegradable\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic vs. Metal: A Comparison – The Conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The choice between plastics and metals ultimately depends on the specific requirements of the application, including design requirements, functionality and cost. Both plastics and metals have their own specific strengths and weaknesses, and the right choice is made by carefully weighing up the various factors.\u003C\u002Fp>\u003Cp>Plastic is a better choice than metal for more cost-effective production and offers a wider range of design options. We’d be happy to advise you! Please get in touch with formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact\u003C\u002Fa> to discuss any queries you may have, including the use of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fwas-sind-biokunststoffe\">bioplastics\u003C\u002Fa> in thermoforming.\u003C\u002Fp>","plastics-vs-metal",{"id":749,"documentId":750,"createdAt":751,"updatedAt":752,"publishedAt":85,"locale":10,"title":753,"introduction":754,"content":755,"slug":756},346,"k15og2ckzlyxayxyfeyfle6w","2026-01-13T15:51:46.857Z","2026-06-03T09:09:14.591Z","What is Pneumatic Forming? A Quick Guide to Shaping Plastic with Compressed Air","Pneumatic forming is a widely used technique for shaping thermoformed parts from rolls or sheets. This process utilizes compressed air to apply greater force during the forming stage, ensuring precise shaping and efficient production.\n\nFind out how pneumatic forming works and the key advantages it offers in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Pneumatic forming – key facts at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Pneumatic forming uses heated material and additional compressed air for precise shaping. It requires robust tooling, often made of aluminium, and a bottom-up approach when building up pressure.\u003C\u002Fli>\u003Cli>\u003Cstrong>Advantages:\u003C\u002Fstrong> sharper contours, improved material distribution, lower risk of chill marks, shorter cycle times and suitability for high-volume production.\u003C\u002Fli>\u003Cli>Pneumatic forming is particularly suitable for demanding thermoforming projects, such as transparent parts, engineering plastics or pre-printed components, despite higher tooling and energy costs compared with vacuum forming.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request your pneumatic-formed thermoformed part now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is pneumatic forming?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Pneumatic forming is a specialised process used in plastic thermoforming and the twin-sheet process. In this method, the heated material is pressed precisely against the tool using additional compressed air. This produces components with particularly sharp contours, uniform wall thicknesses and high precision.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Interested in how pneumatic forming differs from \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fvacuum-forming\">What is plastic vacuum forming?\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does pneumatic forming work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In pneumatic forming, the heated semi-finished material, either \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">sheet\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">roll \u003C\u002Fa>material, is pressed against the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">tool \u003C\u002Fa>using compressed air. Since high forces are involved, robust aluminium tools are required. Prototype materials such as Ureol or synthetic resins cannot withstand the pressure and could damage the machine.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPneumatic_forming_ee7fb56e37.webp\" alt=\"Pneumatic forming\">\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Process steps in pneumatic forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Heating the material:\u003C\u002Fstrong> The plastic is brought to forming temperature.\u003C\u002Fli>\u003Cli>\u003Cstrong>Pressure build-up:\u003C\u002Fstrong> The process starts with low pressure, which is then gradually increased (“bottom-up”) until the optimum forming result is achieved.\u003C\u002Fli>\u003Cli>\u003Cstrong>Forming:\u003C\u002Fstrong> Compressed air presses the plastic precisely into the cavity.\u003C\u002Fli>\u003Cli>\u003Cstrong>Optional pre-stretching:\u003C\u002Fstrong> Bubble forming or the use of a plug assist can help achieve uniform wall thicknesses.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cooling and removal:\u003C\u002Fstrong> The part is released from the tool and is ready for further processing.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ A bottom-up approach is important for achieving the optimum forming pressure during hot forming with compressed air. This means starting with low pressure and gradually increasing it as needed. The pressure should only be as high as necessary to achieve sharp forming of the moulded part. Excessive pressure increases lead to wasted energy and, at the same time, increase the risk of tool damage during production.\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Special processes in pneumatic forming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Pneumatic forming enables the use of specific forming techniques to control wall thickness distribution and geometries in a targeted way.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Pre-stretch bubble:\u003C\u002Fstrong> Before the vacuum and plug assist are applied, a bubble can be formed to pre-stretch the heated material.\u003C\u002Fli>\u003Cli>\u003Cstrong>Snapback process:\u003C\u002Fstrong> The snapback process works with additional compressed air from the lower table.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPneumatic_forming_with_plug_assist_c0871a5788.webp\" alt=\"Pneumatic forming with plug assist\">\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPneumatic_forming_with_snapback_process_59464062a6.webp\" alt=\"Pneumatic forming with snapback process\">\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and limitations of pneumatic forming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Although pneumatic forming machines are more expensive to purchase, the process offers key advantages in terms of precision, cycle time and material distribution.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of pneumatic forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Shorter heating and cooling times:\u003C\u002Fstrong> The process control significantly reduces cycle times. This lowers unit costs, especially for high production volumes.\u003C\u002Fli>\u003Cli>\u003Cstrong>Lower risk of material sagging:\u003C\u002Fstrong> Since lower forming temperatures are used, the material remains stable. The additional forming pressure supports precise forming.\u003C\u002Fli>\u003Cli>\u003Cstrong>Sharp contours and uniform wall thicknesses:\u003C\u002Fstrong> Pneumatic forming optimises contour definition and improves material distribution. At the same time, the risk of chill marks on the surface is reduced.\u003C\u002Fli>\u003Cli>\u003Cstrong>Suitable for high quantities:\u003C\u002Fstrong> Higher tooling costs amortise quickly when the system is used for large series.\u003C\u002Fli>\u003Cli>\u003Cstrong>Meets high visual and mechanical requirements:\u003C\u002Fstrong> The process is ideal for transparent parts and engineering plastics such as PC, polycarbonate, which require high temperature resistance. Pre-printed parts can also be formed much more cleanly with pneumatic forming than with pure vacuum forming.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Disadvantages of pneumatic forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Higher tooling costs than vacuum forming\u003C\u002Fli>\u003Cli>Higher energy consumption due to pressure build-up\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of pneumatic forming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of pneumatic forming\u003C\u002Fth>\u003Cth>Disadvantages of pneumatic forming\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Sharper contour definition than vacuum forming\u003C\u002Ftd>\u003Ctd>Higher tooling costs than with vacuum forming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Lower risk of chill marks\u003C\u002Ftd>\u003Ctd>Higher energy costs than with vacuum forming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>High temperature resistance\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Shorter cycle times\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Suitable for large quantities\u003C\u002Ftd>\u003Ctd>\u002F\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Pneumatic forming – conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Pneumatic forming is an effective method for precise and economical thermoforming of plastics. The combination of targeted compressed air application and robust tools enables sharp forming. Despite higher initial investments, pneumatic forming machines offer advantages over vacuum forming machines thanks to shorter cycle times and higher temperature resistance.\u003C\u002Fp>\u003Cp>Pneumatic forming is particularly suitable for projects with high quantities and demanding requirements, such as transparent engineering plastics or pre-printed parts. This makes pneumatic forming a cost-efficient, high-quality solution. Do you want to get started with your thermoforming project? Then submit your request now via our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator!\u003C\u002Fa>\u003C\u002Fp>","pneumatic-forming",{"id":758,"documentId":759,"createdAt":760,"updatedAt":761,"publishedAt":85,"locale":10,"title":762,"introduction":763,"content":764,"slug":765},373,"xv9se23qc5esajjy35n4d3lw","2026-01-13T15:51:51.994Z","2026-06-02T18:02:39.799Z","What Is a Workpiece Carrier? Definition & Applications","A constant challenge in the manufacturing industry is efficiently managing material flow throughout all assembly stages and departments. These logistical challenges can be optimally addressed by using product-specific workpiece carriers. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Workpiece carriers – Key facts at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Workpiece carriers\u003C\u002Fstrong> transport, secure and protect workpieces, optimise material flow and enable automation in manufacturing.\u003C\u002Fli>\u003Cli>Workpiece carriers offer \u003Cstrong>features\u003C\u002Fstrong> such as coding, RFID, compatibility with stacking and conveyor systems, and ergonomic handling to improve efficiency.\u003C\u002Fli>\u003Cli>\u003Cstrong>Plastic versions \u003C\u002Fstrong>are lightweight, gentle on delicate parts and, depending on the material thickness, suitable for single-use or durable, reusable applications.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Enquire about workpiece carriers now\u003C\u002Fa>\u003C\u002Fp>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">→ Generate 3D tray now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is a workpiece carrier?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>A workpiece carrier, also known as a parts carrier, load carrier, tray or workpiece holder, is used to \u003Cstrong>transport\u003C\u002Fstrong>, \u003Cstrong>secure\u003C\u002Fstrong> and \u003Cstrong>protect\u003C\u002Fstrong> workpieces during the manufacturing process. Workpiece carriers are used in various industries, including \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">food production\u003C\u002Fa> and other sectors.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FWerkstuecktraeger_7ae6aaee4c.png\" alt=\"Werkstückträger für verschiedene Funktionen und Anwendungen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">The functions of workpiece carriers explained in more detail:\u003C\u002Fspan>\u003C\u002Fh3>\u003Ch4>Fixing and positioning\u003C\u002Fh4>\u003Cp>Workpiece carriers are used to hold the workpieces securely in place and keep them in the desired position. This is particularly important for sensitive parts.\u003C\u002Fp>\u003Ch4>Protection against damage\u003C\u002Fh4>\u003Cp>Workpiece carrier transport systems ensure that workpieces are protected during \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">transport and storage.\u003C\u002Fa> Components can be fixed in such a way that sensitive component areas do not come into contact with the wall. They are also protected from falling out and vibrations during transport by fixings and customised nests.\u003C\u002Fp>\u003Ch4>Automation and efficiency\u003C\u002Fh4>\u003Cp>In automated production systems, workpiece carriers enable a smooth material flow. Workpiece carrier systems are often designed so that they can be seamlessly integrated into automated systems and enable robotic handling. You can find more on this topic under \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-production-automation\">\"Automation trays.\"\u003C\u002Fa>\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Ideally, the entire process across the various manufacturing stages of a component is seamlessly covered by a \u003Cb>single workpiece carrier system\u003C\u002Fb>. This enables end-to-end automation of production processes, component cleaning, warehousing and logistics.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">The role of workpiece carriers for Industry 4.0\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Industry 4.0 requires the consistent automation of production processes to enable cross-technology integration of systems. To ensure that all robots and automation components can optimally control, pick up, process and smoothly transfer components to the next stage of production, consistent production conditions are essential. \u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Workpiece carriers as the basis for stable processes\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>These conditions are ensured, amongst other things, by the use of flexible workpiece carriers. They ensure that components can be positioned precisely and transported smoothly, regardless of their size or shape.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transport along the production line\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Workpiece carriers play a key role in this process:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Transport of semi-finished components, assemblies or products\u003C\u002Fstrong> from station to station\u003C\u002Fli>\u003Cli>\u003Cstrong>Adaptation to conveyor systems\u003C\u002Fstrong> such as belts, roller conveyors or workpiece conveyors\u003C\u002Fli>\u003Cli>\u003Cstrong>Integration into the process logic\u003C\u002Fstrong>, so that the tray operates seamlessly within the production flow\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Workpiece carriers are therefore essential for efficient, digitally controlled manufacturing processes in Industry 4.0.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How do workpiece carriers ensure optimised production and logistics?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers play a decisive role in the optimisation of manufacturing and logistics processes. Here are some aspects of how they can contribute to this:\u003C\u002Fspan>\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Coding and product recognition\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Various electronic and optical methods are available to ensure that machines and systems can recognise both components and the workpiece carrier.\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCodierung_und_Produkterkennung_bei_Werkstuecktraegern_04b5ca29d0.png\" alt=\"Werkstückträger ermöglichen Codierung und Produkterkennung\">\u003C\u002Ffigure>\u003Ch4>Placeholders for adhesive labels or label pockets\u003C\u002Fh4>\u003Cp>Replaceable or fixed labels are an effective and frequently used method of product labelling. For labels, space can be saved at an early stage on the tray edge and the stacking cams can be designed to fit around them.\u003C\u002Fp>\u003Ch4>Integrated RFID transponders\u003C\u002Fh4>\u003Cp>Electronic devices that transmit data wirelessly via radio frequencies can be integrated into the workpiece carrier. It is possible to provide space for an RFID transponder or alternative tracking devices at an early stage on the edge of the workpiece carrier.\u003C\u002Fp>\u003Ch4>Coding strip\u003C\u002Fh4>\u003Cp>For mechanical testing, BCD coding with moulded studs or milled cuts can be applied to the edge of the part carrier or the frame.\u003C\u002Fp>\u003Ch4>Colour stripes\u003C\u002Fh4>\u003Cp>An additional coloured stripe on the workpiece carrier can be used for visual alignment and orientation. Images and more information on trays with colour stripes can be found on our product pages.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Alignment and positioning\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>To ensure that the sensor system reliably recognises components and prevents the robot gripper from colliding during loading and unloading, the workpiece carrier offers various solutions.\u003C\u002Fp>\u003Ch4>Gripper and fork recesses\u003C\u002Fh4>\u003Cp>If trays need to be separated individually (with a fork or grippers), recesses or grooves can be provided for dipping.\u003C\u002Fp>\u003Ch4>Recesses for centring cones\u003C\u002Fh4>\u003Cp>Recesses for centring cones can be attached to the edge of the nest to align the workpiece carriers. The centring bar is used to secure the workpiece carrier during loading and unloading or on the conveyor belt.\u003C\u002Fp>\u003Ch4>Poka-Yoke corners\u003C\u002Fh4>\u003Cp>The term \"poka-yoke\" comes from the Japanese and means \"avoid mistakes\". Poka-yoke corners are used for visual orientation to avoid errors such as incorrect insertion or alignment of the workpiece holder. For correctly aligned workpiece holder insertion, a chamfer can be made in one of the corners or a coloured stripe can be placed on one side.\u003C\u002Fp>\u003Ch4>Anti-twist protection \u002F stacking protection\u003C\u002Fh4>\u003Cp>An anti-twist device guarantees correct alignment when stacking several workpiece carriers on top of each other by means of mechanical stacking protection. This can also be designed for different tray variants so that the workpiece carriers can only be stacked by type.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transport\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Workpiece carriers also support the transport of components. The transport of components using the trays is ensured by efficient stacking, adaptation to conveyor systems and ergonomic handling.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:31.32%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStapelung_von_Werkstuecktraegern_e6a854e2e3.jpg\" alt=\"Effiziente Stapelung durch Werkstückträger\">\u003C\u002Ffigure>\u003Ch4>Stacking technology\u003C\u002Fh4>\u003Cp>Workpiece carriers are stackable. They can be stacked on top of each other effortlessly and stably without external aids. Various stacking techniques are available, including undercut or dimple stacking, which can be flexibly adapted to your transport and handling requirements.\u003C\u002Fp>\u003Cp>It is important to consider the following aspects in the design:\u003C\u002Fp>\u003Cul>\u003Cli>The sensitivity of the parts\u003C\u002Fli>\u003Cli>The desired number of layers\u003C\u002Fli>\u003Cli>The maximum height of the packaging unit\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The deep-drawn workpiece carriers can be designed so that they can be stacked free-standing on Euro pallets or integrated into cartons or small load carriers. The stacking is adapted to the palletising system used and also includes an anti-twist device for stacking protection. You can find even more information on \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fstacking-methods-for-trays\">stacking techniques in our blog.\u003C\u002Fa>\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Palletisers are available in various designs (drawer systems, lift systems, tray stackers). Your workpiece carrier is designed to suit the stages of the production line.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch4>Adaptation to conveyor systems\u003C\u002Fh4>\u003Cp>Conveyor belt systems are used in the form of roller conveyors, belt conveyors and floor conveyors. The underside of your workpiece carrier is designed according to the requirements of your transport system.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:28.45%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FAnpassung_an_Foerdersysteme_2188301975.png\" alt=\"Anpassung der Werkstückträger an Fördersysteme\">\u003C\u002Ffigure>\u003Ch4>Ergonomic handling\u003C\u002Fh4>\u003Cp>Ergonomically designed recessed grips on the sides of the workpiece carriers facilitate ergonomic loading of the trays in the KLT or outer carton. This means that the trays can be easily gripped, held, carried, removed from the carton or placed back into the carton.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:22.45%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGriffmulden_des_Werkstuecktraegers_1_0b09491900.jpg\" alt=\"Griffmulden ermöglichen ergonomisches Handling der Werkstückträger\">\u003C\u002Ffigure>\u003Cp>It is advisable to consider the size and position of the handles on the workpiece carrier at an early stage, as this also influences the shape of the nests and the stacking.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Ftray-generator\">3D Tray Generator \u003C\u002Fa>, you can upload 3D data for your tray and customise properties such as stacking height, dimensions, markings and more.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why plastic workpiece trays? The advantages\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F6_werkstuecktraeger_tray_5b1ad7a56d.webp\" alt=\"Gefüllter Kunststoff Werkstückträger mit Bauteilen\">\u003C\u002Fp>\u003Cp>Workpiece carriers can be made of various materials, including \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastics-vs-metal\">plastic or metal\u003C\u002Fa>. Plastic carriers are lighter and easier to handle than conventional metal cleaning baskets. The plastic material of the workpiece carriers therefore makes handling easier and, due to the plastic properties, promotes gentle handling of the sensitive workpieces.\u003C\u002Fp>\u003Cp>Depending on the area of application, plastic workpiece carriers are usually made of materials such as PET-A, PS or ABS. Plastic trays often have special properties such as\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection\u003C\u002Fa>\u003C\u002Fli>\u003Cli>resistance to chemicals\u003C\u002Fli>\u003Cli>or integration into cleaning processes.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The service life (disposable or reusable, over months or years) of the load carrier influences the design of the workpiece carrier. Thanks to variable material thicknesses, plastic pallets can be designed to be either very stable, durable and resilient for reusable use as returnable packaging.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:25.88%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefzieh_Transport_Einweg_Mehrweg_1dfc761d52_aca5821727.jpg\" alt=\"Einsatzdauer von Werkstückträgern\">\u003C\u002Ffigure>\u003Cp>This is achieved through increased material thicknesses and stabilising elements such as ribbing and struts. Alternatively, plastic workpiece carriers can be designed for single-use in an extremely material-saving and cost-effective way.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Areas of application for plastic workpiece carriers\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Find out more about the areas of application for plastic workpiece carriers:\u003C\u002Fspan>\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD workpiece carriers for electronics\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftrays-with-color-stripes\">Tray with colour stripes\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fload-carriers-for-automotive\">Workpiece carrier for automotive\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftray-packaging-for-metal-parts\">Tray packaging for metal parts\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Workpiece carriers enable efficient processes - A summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In the world of manufacturing, workpiece carriers are indispensable aids that ensure the smooth running of production processes. From fixing and positioning to protection against damage, they fulfil various functions to optimise the quality of the end products and increase efficiency.\u003C\u002Fp>\u003Cp>Do you need workpiece carriers for your components? Then configure your plastic tray now!\u003C\u002Fp>","what-is-a-workpiece-carrier",{"id":767,"documentId":768,"createdAt":769,"updatedAt":770,"publishedAt":85,"locale":10,"title":771,"introduction":772,"content":773,"slug":774},367,"tudg9nipwzcuck9nhsk43pad","2026-01-13T15:51:50.846Z","2026-06-03T10:18:51.981Z","What is Plastic Vacuum Forming? A Brief Explanation of Vacuum Thermoforming","Vacuum forming is a method that uses vacuum and compressed air to shape plastic parts from rolls or sheets. In this process, also known as vacuum thermoforming, the vacuum pump plays a crucial role. In this article, we explain the key aspects of the vacuum forming process.","\u003Ch2>Plastic vacuum forming - The essentials in brief\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Plastic vacuum forming\u003C\u002Fstrong> is a thermoforming process in which heated plastic sheets are drawn into a mold using negative pressure to produce components.\u003C\u002Fli>\u003Cli>Vacuum forming is particularly suitable for \u003Cstrong>small to medium series\u003C\u002Fstrong>, as the tools are inexpensive, energy consumption is low and production times are comparatively short.\u003C\u002Fli>\u003Cli>\u003Cstrong>Typical applications\u003C\u002Fstrong> are found in packaging, automotive and medical technology, for example for trays, inlays or simple housing parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request vacuum-formed thermoformed part now!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>How does plastic vacuum forming work?\u003C\u002Fh2>\u003Cp>Plastic vacuum forming is a process in which vacuum and, if necessary, compressed air are used to produce formed thermoformed parts from \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">plastic sheets\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">rolls\u003C\u002Fa>. It is one of the oldest \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoforming processes\u003C\u002Fa> and is still used in many industries today.\u003C\u002Fp>\u003Ch3>Difference to other thermoforming processes\u003C\u002Fh3>\u003Cp>While \u003Cstrong>negative pressure\u003C\u002Fstrong> is generated in vacuum forming, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpneumatic-forming\">pneumatic forming\u003C\u002Fa> additionally works with compressed air to apply greater force during the forming process. This article focuses on classic vacuum forming.\u003C\u002Fp>\u003Ch2>How are the molds for vacuum forming produced?\u003C\u002Fh2>\u003Cp>In plastic vacuum forming, the heated semi-finished product (sheet or roll) is drawn over the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">tool\u003C\u002Fa> using negative pressure. A vacuum pump generates a vacuum of approximately \u003Cstrong>1 bar\u003C\u002Fstrong>, so that the air between the material and tool surface is extracted. As a result, the material conforms closely to the tool contours and takes on the desired shape.\u003C\u002Fp>\u003Ch3>Process in vacuum forming\u003C\u002Fh3>\u003Col>\u003Cli>Heating the semi-finished product to forming temperature.\u003C\u002Fli>\u003Cli>Placing the material on the forming tool.\u003C\u002Fli>\u003Cli>Extracting the air through the vacuum pump → The negative pressure presses the material into the tool contours.\u003C\u002Fli>\u003Cli>Cooling of the plastic → Removal of the formed part.\u003C\u002Fli>\u003C\u002Fol>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1995\u002F788;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FVaccuum_Plastic_Forming_Process_simplified_7376df4a4a.webp\" alt=\"Simplified plastic vacuum forming process\" width=\"1995\" height=\"788\">\u003Cfigcaption>Simplified representation of the plastic vacuum forming process\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Typical problem in vacuum forming\u003C\u002Fh3>\u003Cp>A frequently occurring problem in plastic vacuum forming is that the negative pressure decreases when the heated material is applied to the tool. However, the greatest forming pressure is needed precisely in this phase of the forming process.\u003C\u002Fp>\u003Ch4>Solution: Two-stage vacuum system\u003C\u002Fh4>\u003Cp>This can be optimized through a \u003Cstrong>two-stage vacuum system\u003C\u002Fstrong>, which requires a vacuum pump with high volume capacity. Here, a second vacuum is generated before the material cools.\u003Cbr>\u003Cstrong>The advantages:\u003C\u002Fstrong> In this way, the material is better distributed into the corners of the tool, and the contours of the molded part become sharper. Radii can also be reproduced smaller in this way.\u003C\u002Fp>\u003Ch2>Where does vacuum forming make sense?\u003C\u002Fh2>\u003Cp>Although plastic vacuum forming has its disadvantages compared to pressure forming in terms of economical production of large series and complex geometries, vacuum thermoforming is sufficient especially for \u003Cstrong>uncomplicated parts\u003C\u002Fstrong> and \u003Cstrong>small volumes\u003C\u002Fstrong>. Due to the low forming pressure, vacuum forming is therefore particularly suitable for relatively simple parts, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">plastic inlays\u003C\u002Fa> for packaging or plastic trays for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">food\u003C\u002Fa>.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️  Interested in how plastic vacuum forming differs from other plastic processing methods? Then feel free to read our articles \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Finjection-molding-vs-thermoforming\">injection molding vs. thermoforming\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fthermoforming-vs-3d-printing\">thermoforming vs. 3D printing.\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>Possibilities and limitations in plastic vacuum forming\u003C\u002Fh2>\u003Cp>Plastic vacuum forming proves to be extremely advantageous for the production of plastic parts, especially for uncomplicated parts and small volumes.\u003C\u002Fp>\u003Ch3>Economic advantages of vacuum forming\u003C\u002Fh3>\u003Cul>\u003Cli>Affordable tooling costs, due to the simpler construction compared to pressure forming tools\u003C\u002Fli>\u003Cli>Lower energy costs in vacuum thermoforming than in pressure forming\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Limitations of vacuum forming\u003C\u002Fh3>\u003Cul>\u003Cli>Less economical for large series\u003C\u002Fli>\u003Cli>Not suitable for complex parts\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Vacuum forming advantages and disadvantages overview\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Advantages of Plastic Vacuum Forming\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Disadvantages of Plastic Vacuum Forming\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Suitable for simple parts\u003C\u002Ftd>\u003Ctd>Lower form sharpness compared to pressure forming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Low tooling costs\u003C\u002Ftd>\u003Ctd>Higher risk of blemishes compared to pressure forming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Lower energy consumption than pressure forming\u003C\u002Ftd>\u003Ctd>Lower temperature resistance than pressure forming\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cost-effective for small production runs\u003C\u002Ftd>\u003Ctd>Longer cycle times than pressure forming\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cp>Nevertheless, it is important to always keep the overall calculation in view. This means that when deciding on plastic vacuum forming, both tooling and molded part costs should be carefully considered.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ In our formary x Illig webinar on \"What is the right process for my thermoformed product?\" you will learn in detail which methodology is best suited for your project.\n\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=_NQr7sFt7JY\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Ch2>Plastic vacuum forming - A conclusion\u003C\u002Fh2>\u003Cp>Plastic vacuum forming offers an economical and efficient solution for the production of plastic parts. It is particularly well suited for uncomplicated parts, small volumes and applications such as packaging inlays or food trays. The advantages, including cost-effective tools, energy efficiency and versatile applicability, make the vacuum forming process a popular choice in various industrial sectors.\u003Cbr>Do you have questions or want to have your thermoformed product manufactured using the vacuum forming process? Then \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact us\u003C\u002Fa> or submit a request via the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa>.\u003C\u002Fp>","vacuum-forming",{"id":776,"documentId":777,"createdAt":778,"updatedAt":779,"publishedAt":85,"locale":10,"title":780,"introduction":781,"content":782,"slug":783},334,"bzmi85ikxzegn669893of6r7","2026-01-13T15:51:44.527Z","2026-06-02T17:05:41.336Z","What is Recyclate? Options in Plastic Recycling and Distinction from Virgin Material","In an increasingly sustainability-oriented world, recycling and the reuse of materials play a key role. Plastic recyclates offer a sustainable alternative to virgin materials. But what exactly does the term mean, and how can recyclates be distinguished from virgin materials? Read more now.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What are recycled materials? – The key points in brief\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>The use of \u003Cstrong>recycled plastic material, \u003C\u002Fstrong>known as recyclates, reduces the environmental impact.\u003C\u002Fli>\u003Cli>There are\u003Cstrong> two main types\u003C\u002Fstrong> of recycled materials: post-industrial recycled materials (PIR) from production waste and post-consumer recycled materials (PCR) from end-consumer waste.\u003C\u002Fli>\u003Cli>The \u003Cstrong>processing \u003C\u002Fstrong>of recycled materials presents challenges for companies, as there are no uniform standards regarding colour standards, processing properties and surface quality.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Enquire now about thermoformed parts made from recycled material\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">The use of recycled materials: the current situation in Germany\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The recycling of plastics is becoming increasingly important in Germany as a means of reducing the environmental impact of plastic waste. Currently, around 50% of plastic waste is recycled, whilst the remainder is used for energy recovery or sent to landfill.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Measures to increase the recycling rate\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>To increase the recycling rate, the Packaging Act was introduced in 2019, which requires companies to make their packaging more environmentally friendly and to ensure it is disposed of properly. The use of recycled plastics is also becoming increasingly popular. The circular economy is to be supported by optimal packaging design (Design for Recycling) in order to minimise environmental impact whilst ensuring optimal product packaging – ideally with the highest possible proportion of recycled material.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ One example of this is our project with our client NAEXT. The company manufactures second-life batteries from electric cars and requires suitable casings to protect them. The housing was made of aluminium, but this was energy-intensive and did not meet NAEXT’s sustainability requirements. We therefore developed a plastic version made from 100% recycled ABS. Read more about the project in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcase-studies\u002Fproject-with-naext\">case study with NAEXT.\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is recycled material?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Recyclates are products created through the recycling process and are literally described as \u003Cstrong>\"reintroduced into the cycle\"\u003C\u002Fstrong>. They are produced from various materials such as glass, paper or batteries. In the plastics sector, recycled materials refer to \u003Cstrong>reused material\u003C\u002Fstrong> such as PE (polyethylene), \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP (polypropylene)\u003C\u002Fa> or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PET (polyethylene terephthalate)\u003C\u002Fa>, which has already been disposed of once by households or businesses and is now being used again to manufacture new products.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:640\u002F427;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FRezyklat_in_Form_von_Kunststoffflakes_64e7a6f185.png\" alt=\"Rezyklat in Form von Kunststoffflakes\" width=\"640\" height=\"427\">\u003Cfigcaption>Recyclate in the form of plastic flakes\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Types of recycled materials\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastic recyclates are available in the form of granules, flakes or powder and are regarded as secondary raw materials.\u003C\u002Fp>\u003Cp>There are \u003Cstrong>two main types\u003C\u002Fstrong> of recyclates:\u003C\u002Fp>\u003Col>\u003Cli>\u003Cstrong>Post-industrial recyclates (PIR) or pre-consumer recyclates:\u003C\u002Fstrong> these are created from excess plastic waste generated during the production of plastic packaging or other plastic products.\u003C\u002Fli>\u003Cli>\u003Cstrong>Post-consumer recyclates (PCR):\u003C\u002Fstrong> In contrast, PCR consists of recycled plastic waste that has been used in households, industry or commerce and subsequently disposed of via the yellow bag or yellow bin.\u003C\u002Fli>\u003C\u002Fol>\u003Ch2>\u003Cspan style=\"color:#005250;\">Recyclates: challenges in plastic thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The use of recyclates always makes sense from a recycling perspective. However, the processing of recyclates is also associated with challenges that need to be taken into account, especially in the case of visually or technically sophisticated \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\">thermoformed products\u003C\u002Fa>:\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:23.24%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FProbleme_Icon_ed57dd64a9.png\" alt=\"Probleme bei Rezyklaten_Icon\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">No uniform colour standards\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Plastics based on recyclates do not have uniform colour standards. Various regenerative components are mixed during the manufacturing process, which means that no RAL colour shade is possible.\u003C\u002Fp>\u003Cp>For example, the colour palette for \"PS Regenerat black\" ranges from anthracite to black and for \"PS Regenerat white\" from a yellowish to a bright white. There is therefore \u003Cstrong>no guarantee \u003C\u002Fstrong>of colour accuracy.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Processing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Recycled materials can be \u003Cstrong>less reliable\u003C\u002Fstrong> to process than virgin materials. This is because recycled materials can come from a wide variety of sources and vary in composition from batch to batch. This can lead to variations in material properties, such as melting point, flow behaviour and mechanical properties.\u003C\u002Fp>\u003Ch4>Material degradation during recycling\u003C\u002Fh4>\u003Cp>During the recycling process, materials may undergo a certain degree of degradation, particularly if they have been recycled several times. This degradation can lead to a deterioration in the material’s properties. Typical consequences include:\u003C\u002Fp>\u003Cul>\u003Cli>lower strength or impact resistance\u003C\u002Fli>\u003Cli>altered melting point\u003C\u002Fli>\u003Cli>poorer flow properties\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This can mean that recycled materials no longer offer the same properties as the original virgin material.\u003C\u002Fp>\u003Ch4>Adjustment of processing parameters\u003C\u002Fh4>\u003Cp>Due to differences in material composition and quality, different processing parameters may be required to process recycled materials effectively. This includes changes to \u003C\u002Fp>\u003Cul>\u003Cli>Application temperature\u003C\u002Fli>\u003Cli>Speed\u003C\u002Fli>\u003Cli>or compressed air.\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Impact on production\u003C\u002Fh4>\u003Cp>Due to the varying parameters involved with recycled material, recycled products may, in some cases, result in a higher reject rate and longer cycle times compared to virgin material in order to achieve a similar level of quality. Furthermore, chipping of the milled edge is a problem that occurs to a greater or lesser extent with recycled material, depending on the quality of the material.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Surface quality\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Due to the variety of raw materials used, there is no guarantee for the surface quality of the deep-drawn part.\u003C\u002Fp>\u003Cp>\u003Cstrong>Complex moulds\u003C\u002Fstrong> with the use of recycled materials can be problematic. This is a particular problem with deep-drawn parts, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">plastic housings\u003C\u002Fa>, where aesthetics play a role.\u003C\u002Fp>\u003Ch4>Problems that can occur on the surface are\u003C\u002Fh4>\u003Cul>\u003Cli>Air pockets\u003C\u002Fli>\u003Cli>Small bubbles\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">No material data sheet\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>It is important to note that the \u003Cstrong>exact origin\u003C\u002Fstrong> of the various recycled components is \u003Cstrong>not always known\u003C\u002Fstrong>. It is therefore not possible to guarantee the absence of silicone. Important: The mechanical properties of individual extrusion batches can usually be determined using laboratory samples. This no longer applies to the next series from a different material batch.\u003C\u002Fp>\u003Cp>This means that there is no material data sheet available that can be used to trace the origin of the plastics.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview: Comparison of recycled plastic and virgin material\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Recycled plastic\u003C\u002Fth>\u003Cth>Plastic virgin material\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>No RAL colour possible\u003C\u002Ftd>\u003Ctd>RAL colour possible\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>No uniform colour standards\u003C\u002Ftd>\u003Ctd>High colour accuracy\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Potential bubbles and air pockets\u003C\u002Ftd>\u003Ctd>Smooth surfaces\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Exact origin of the recycled components not known\u003C\u002Ftd>\u003Ctd>Origin known\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>No material data sheet available\u003C\u002Ftd>\u003Ctd>Material data sheet available\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Potential degradation\u003C\u002Ftd>\u003Ctd>Consistent quality at all times\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">How is recyclate produced?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The conversion of waste into recycled materials involves a \u003Cstrong>multi-stage process.\u003C\u002Fstrong> \u003C\u002Fp>\u003Col>\u003Cli>\u003Cstrong>Collection: \u003C\u002Fstrong>To produce recycled materials, recyclable plastic products such as packaging are first disposed of in the yellow bag or bin rather than in the general waste, ensuring that they enter the recycling cycle at least once.\u003C\u002Fli>\u003Cli>\u003Cstrong>Sorting: \u003C\u002Fstrong>The pre-sorted waste is taken to recycling centres, where it is separated by plastic type and colour using modern sorting equipment.\u003C\u002Fli>\u003Cli>\u003Cstrong>Shredding and compaction:\u003C\u002Fstrong> The waste plastic is compressed, shredded, or both processes are carried out in succession.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cleaning: \u003C\u002Fstrong>A thorough cleaning is carried out to remove foreign plastics or other foreign materials.\u003C\u002Fli>\u003Cli>\u003Cstrong>Further processing: \u003C\u002Fstrong>The cleaned material is processed into\u003Cstrong> \u003C\u002Fstrong>flakes or granules\u003Cstrong> \u003C\u002Fstrong>. The resulting recycled plastic is then used as a raw material for new products or semi-finished goods.\u003C\u002Fli>\u003C\u002Fol>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is the difference between recyclate, regranulate and reclaim?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Recyclate is the \u003Cstrong>generic term\u003C\u002Fstrong> for regranulate and reclaim.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cspan style=\"color:#0c0c0c;\">\u003Cstrong>Regranulate:\u003C\u002Fstrong>\u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\"> \u003C\u002Fspan>Depending on requirements and subsequent use, it may be necessary to produce regranulate from the used plastic. Recycled pellets are obtained from recyclable plastics without additives - from the ground, shredded plastics via a melting process.\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:#0c0c0c;\">\u003Cstrong>Regenerate\u003C\u002Fstrong>\u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>:\u003C\u002Fstrong>\u003C\u002Fspan> Regenerate is also produced by a melting process (compounding). By adding additives, various properties of the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">materials \u003C\u002Fa>can be defined and customised according to requirements.\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>\u003Cspan style=\"color:#005250;\">Recyclates in thermoforming\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>In the thermoforming sector, recycled plastic is used as a raw material for the production of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">plastic films\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">sheets \u003C\u002Fa>by means of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastic extrusion\u003C\u002Fa>, which can then be used for the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoforming of plastic\u003C\u002Fa>.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How is recycled material labelled?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>To label plastics that have already undergone a recycling process and are therefore different from primary plastics, the letter \"R\" is often placed in front of the material name. For example, rPET, rPP, rHDPE, rLDPE and so on. In this context, the \"R\" stands for \"recycled\" and is often written in lower case.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Legal requirements for recyclates\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>REACH Regulation (EC) No. 1907\u002F2006 - REACH conformity\u003C\u002Fli>\u003Cli>RoHS Directives (EU) No. 2011\u002F65 and Annex ⅠⅠ according to Directive (EU) No. 2015\u002F863 - RoHS conformity\u003C\u002Fli>\u003Cli>All requirements of Annex XVII of the REACH Regulation regarding restrictions\u003C\u002Fli>\u003Cli>The Waste Framework Directive (EC) No. 2008\u002F98:2018 on waste\u003C\u002Fli>\u003Cli>The GS specification AfPS GS 2019:01 PAH for category 2 - Other consumer products\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic recycling with formary\u003C\u002Fspan>\u003C\u002Fh2>\u003Ch3>Recycling of production waste\u003C\u002Fh3>\u003Cp>All production waste, such as die-cutting and milling scraps, is collected and returned to the material cycle. These scraps are used to produce new granulate, which is then used to manufacture new films and sheets.\u003C\u002Fp>\u003Ch3>Post-Consumer-Recycling\u003C\u002Fh3>\u003Cp>The post-consumer cycle is beyond formary’s direct control, as end users are responsible for disposing of the products properly. If the end user is a business, all parts can be fully recycled at the end of their useful life. formary therefore takes back old thermoformed parts and reuses them.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa>, you can specify whether you want your plastic to be made from recycled material. Under “Material”, you can select recycled plastic as the desired option for your thermoformed product.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">The use of recycled plastics - a summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The use of recyclates is widespread in the thermoforming industry and is seen as an important step towards a more sustainable use of plastics. Thermoformers generally utilise the leftover material from thermoforming and grind it up to produce the plastics as recyclates for the re-production of thermoformed parts.\u003C\u002Fp>\u003Cp>However, there are still challenges in the production of high-quality plastic products, which can have sources of error, particularly in terms of aesthetics. It is therefore always worth consulting specialists if you want to use recyclates or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-are-bioplastics\">bioplastics \u003C\u002Fa>for your thermoforming project.\u003C\u002Fp>\u003Cp>If you have any questions about the use of recyclates, please \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact us\u003C\u002Fa>! We will be happy to help you.\u003C\u002Fp>","what-is-recyclate",{"id":785,"documentId":786,"createdAt":787,"updatedAt":788,"publishedAt":85,"locale":10,"title":789,"introduction":790,"content":791,"slug":792},351,"mlnpx89wcd3xb7bjpl8rwkq0","2026-01-13T15:51:47.821Z","2026-06-02T16:43:33.085Z","What Are Bioplastics? Definition, Applications, Advantages, and Limitations","Bioplastics are plastics that are either made from renewable raw materials or are biodegradable - or both. They offer a wide range of possible applications - but what exactly are bioplastics, how are they produced and what advantages or limitations do they have compared to traditional plastics?","\u003Ch2>\u003Cspan style=\"color:#005250;\">Bioplastics – Key facts at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Definition:\u003C\u002Fstrong> Bioplastics are either bio-based (made from renewable raw materials) or biodegradable; some are both.\u003C\u002Fli>\u003Cli>\u003Cstrong>Applications:\u003C\u002Fstrong> Bio-based plastics are used in packaging, medical devices, the automotive industry and consumer goods.\u003C\u002Fli>\u003Cli>\u003Cstrong>Advantages:\u003C\u002Fstrong> Reduced dependence on oil, potentially lower CO₂ emissions, biodegradability.\u003C\u002Fli>\u003Cli>\u003Cstrong>Limitations:\u003C\u002Fstrong> Requires a large amount of space for raw materials, limited recyclability, higher costs, not suitable for high-performance applications.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are bioplastics?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Bioplastics explained simply: Bioplastics, also known as bioplastics or technical biopolymers, are plastics that are either completely or partially made from renewable raw materials, i.e. biobased and\u002For biodegradable. In comparison, conventional \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic materials\u003C\u002Fstrong>\u003C\u002Fspan> are based on fossil raw materials.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What types of bioplastics are there?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Bioplastics can primarily be divided into two main categories: Bio-based and biodegradable plastics. In the following section, we present some examples of bioplastics to give you an overview of the different types of bioplastics.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Biobased plastics\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>What does bio-based mean? Bio-based plastics are made from biological, renewable raw materials such as corn starch, sugar cane or cellulose. Bio-based bioplastics are not necessarily biodegradable.\u003C\u002Fp>\u003Cp>Bioplastic properties, such as mouldability, hardness, elasticity, breaking strength, temperature resistance, heat resistance and chemical resistance, vary depending on the composition, manufacturing process and the addition of additives.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics Overview: Bio-based plastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Polylactic acid (PLA):\u003C\u002Fstrong> Made from fermented plant starch and biodegradable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Bio-polyethylene (bio-PE):\u003C\u002Fstrong> Made from sugar cane and not biodegradable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Bio-polyethylene terephthalate (bio-PET):\u003C\u002Fstrong> Partly made from renewable raw materials (e.g. ethanol from sugar cane). Chemically identical to conventional polyethylene, therefore not biodegradable.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FZuckerrohr_0fbe2f9765.jpg\" alt=\"Zuckerrohr\">\u003Cfigcaption>Sugar cane\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Biodegradable plastics\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Biodegradable plastics are produced by natural processes (microorganisms such as bacteria or fungi), which can be broken down into natural substances such as water, carbon dioxide (CO2) and biomass. Bioplastics degrade under certain environmental conditions that are necessary for the activity of the microorganisms (more on this later).\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics overview: Biodegradable plastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Polyhydroxyalkanoates (PHA):\u003C\u002Fstrong> Fermented by bacteria.\u003C\u002Fli>\u003Cli>\u003Cstrong>Polybutylene succinate (PBS):\u003C\u002Fstrong> Can be produced from renewable or fossil raw materials.\u003C\u002Fli>\u003Cli>\u003Cstrong>Polycaprolactone (PCL):\u003C\u002Fstrong> Made from fossil raw materials.\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPilze_aus_denen_biologisch_abbaubare_Kunststoffe_entstehen_koennen_3795d63bd6.jpg\" alt=\"Pilze, aus denen biologisch abbaubare Kunststoffe entstehen können\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics overview: Bio-based and biodegradable plastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Some bioplastics fulfil both criteria: The biopolymers are both biobased and biodegradable.\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Polylactic acid (PLA):\u003C\u002Fstrong> Made from plant starch and biodegradable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Polyhydroxyalkanoates (PHA):\u003C\u002Fstrong> Fermented by bacteria from renewable raw materials and biodegradable.\u003C\u002Fli>\u003Cli>\u003Cstrong>Starch-based plastics:\u003C\u002Fstrong> Made from plant starch and biodegradable.\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Overview of all types of bioplastics\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Bioplastics category\u003C\u002Fth>\u003Cth>Bio-based plastics\u003C\u002Fth>\u003Cth>Biodegradable plastics\u003C\u002Fth>\u003Cth>Bio-based and biodegradable plastics\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Bioplastics examples\u003C\u002Ftd>\u003Ctd>Bio-PE, Bio-PET, PLA\u003C\u002Ftd>\u003Ctd>PHA, PBS, PCL\u003C\u002Ftd>\u003Ctd>Starch-based plastics, PLA, PHA\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Raw materials\u003C\u002Ftd>\u003Ctd>Renewable raw materials (e.g. sugar cane, plant starch)\u003C\u002Ftd>\u003Ctd>Microorganisms, various raw materials\u003C\u002Ftd>\u003Ctd>Plant starch, bacteria\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cp>The properties of bio-based plastics and biodegradable plastics vary depending on the raw material used and the manufacturing processes. In principle, bioplastics can have the same properties as conventional polymers. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">Plastic films \u003C\u002Fa>made from bioplastics are also produced by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastic extrusion\u003C\u002Fa>, just like conventional thermoplastics.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">What can bioplastics be used for? - Products made from bioplastics\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The properties of bioplastics vary depending on the raw materials used and the manufacturing processes. In principle, bioplastics can have the same properties as conventional polymers. Plastic films made of bioplastics are also produced by \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastic extrusion\u003C\u002Fa> like conventional thermoplastics.\u003C\u002Fp>\u003Cp>However, bioplastics are not suitable for high-performance applications. The use of bio-based materials is restricted by limited quantities, price and qualities, based on limited raw materials and higher manufacturing costs. Currently, bioplastics can be used primarily for these applications:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Packaging material \u002F agriculture:\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Packaging products made from compostable bioplastics, such as trays for vegetables, fruit, eggs and meat, containers for drinks and dairy products and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-cosmetic-packaging\">cosmetics packaging.\u003C\u002Fa>\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Medicine \u002F Pharmaceuticals\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>For bioplastics in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medicine and pharmaceuticals,\u003C\u002Fa> the focus is on the resorbability of the products, such as suture materials or implants, which can be broken down by the body after use.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n    \u003Cp>ℹ️ For anyone involved in developing medical blister packs: find out in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Frelevance-of-thermoformed-blisters-in-medical-technology\">white paper\u003C\u002Fa> which plastics are suitable for sterile, validatable and increasingly sustainable medtech packaging – including options using bio-based materials.\u003C\u002Fp>\n\u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive engineering\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bio-based materials are used in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive\u003C\u002Fa> sector in a “sandwich construction”. The core of the component is made of bio-based polymer, with a layer of higher-quality conventional material applied on top (e.g. for visual appearance, feel and functionality).\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Bioplastics vs. plastics: advantages and disadvantages\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Bioplastics have both advantages and limitations compared to conventional plastics, with the latter influencing their suitability for various applications. Here, we take a detailed look at the differences and challenges associated with bioplastics compared to conventional thermoplastics.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of bioplastics\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The use of biopolymers offers a number of advantages, including:\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Renewable raw materials\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Crude oil is a finite resource. In contrast, renewable resources are inexhaustible. This is because bioplastics are made from raw materials such as maize, sugar cane or cellulose, which reduces our dependence on fossil fuels.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Potential for lower CO2 emissions\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Starch from plants is used for the production of bioplastics. These plants extract CO2 from the atmosphere for their growth. When the bioplastic is incinerated, only the amount of CO2 previously absorbed by the plant is released. This creates a \u003Cstrong>closed CO2 cycle.\u003C\u002Fstrong>\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Biodegradability\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Some bioplastics, such as PLA and PHA, are biodegradable\u002Fcompostable and decompose under certain conditions (e.g. in industrial composting plants) into harmless substances such as CO2, water and biomass.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics disadvantages\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Despite the advantages mentioned, however, there are several disadvantages that must be taken into account when assessing their environmental friendliness and practicality. Here are the main challenges and disadvantages of bioplastics in detail.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">High land requirements\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The cultivation of raw materials for bioplastics requires agricultural land that could also be used for food production. This can lead to competition for agricultural resources.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Energy and resource consumption\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Bioplastics = better environment - unfortunately this is not true in terms of energy and resource consumption. The production of bioplastics can be energy-intensive and require high water consumption, which can have a negative impact on their environmental footprint.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Degradation conditions\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Many bio-based and biodegradable plastics require special conditions (e.g. industrial composting plants) for degradation, which are not always available everywhere or require energy.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Costs\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>The prices of bioplastics are often more expensive than conventional plastics, which can limit their widespread use.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Limited recycling options\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffgranulat_in_den_Haenden_ff39ee0490.png\" alt=\"Kunststoffgranulat in den Händen\">\u003C\u002Ffigure>\u003Cp>Without specialised recycling processes tailored to the specific material stream, bioplastics cannot be recycled into new material, unlike conventional \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-recyclate\">recycled plastic\u003C\u002Fa>. Recycling bioplastics is therefore challenging, as biodegradable plastics often require a longer retention time in composting facilities.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Bioplastics in thermoforming\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Can bioplastics now also be used for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic thermoforming\u003C\u002Fa> and thus for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">trays\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">containers\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">inlays\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">covers\u003C\u002Fa>? And how do bioplastics perform compared to conventional thermoplastics? More on this in the following sections.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FBiokunststoffe_im_Kunststoff_Tiefziehen_e356821fc2.png\" alt=\"Biokunststoffe im Kunststoff Tiefziehen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bioplastics have different properties compared to conventional plastics. Some bio-based plastics, such as polylactic acid (PLA) and polyhydroxyalkanoates (PHA), are thermoplastic and can therefore theoretically be used for thermoforming.\u003C\u002Fp>\u003Cp>However, due to their different structure, bioplastics have special requirements in terms of temperature and processing that may differ from those of conventional plastics. Adapting moulding tools to the specific properties of bioplastics can therefore incur additional costs.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Processing parameters\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The processing temperatures and times for bioplastics can vary. PLA, for example, has a lower processing temperature compared to many standard plastics such as polyethylene (PE) or polypropylene (PP).\u003C\u002Fp>\u003Cp>Some bioplastics are hygroscopic, which means that they absorb moisture from the environment. This can lead to processing problems such as bubble formation or undesirable material changes.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Mechanical properties\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bioplastics often have different mechanical properties than traditional plastics. Some may be less impact resistant\u003Cstrong> \u003C\u002Fstrong>or less elastic, which influences the choice of applications. The strength and flexibility must be carefully tested to ensure that the end products meet the requirements.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Want to get started on your thermoforming project but not sure which plastic to choose? Our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-2\">6-step guide\u003C\u002Fa> explains the criteria you need to consider when selecting the right material. \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Is bioplastic an alternative? - A conclusion\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The market share of bioplastics currently stands at around 1%. Consequently, there is still considerable untapped potential when it comes to the use of biopolymers in thermoforming. The advantages of bioplastics are a major factor in their wider adoption: biodegradability, lower CO₂ emissions and the conservation of resources. However, the use of bioplastics also has its limitations and drawbacks. Not only can bioplastic products not compete with standard thermoplastics when it comes to high-performance applications, but their production can also consume significant amounts of agricultural resources.\u003C\u002Fp>\u003Cp>Biopolymers often require specific conditions for decomposition and do not break down completely in conventional composting facilities. Furthermore, there is currently a lack of efficient recycling processes, meaning that incineration remains the most common method of disposal. Another important factor is that bioplastics are often more expensive to produce than conventional plastics, which reduces their economic appeal. However, if the market share of bioplastics were to grow and exceed 1%, these aspects could change.\u003C\u002Fp>","what-are-bioplastics",{"id":794,"documentId":795,"createdAt":796,"updatedAt":797,"publishedAt":85,"locale":10,"title":798,"introduction":799,"content":800,"slug":801},348,"kmwdd65q4ti6vu8naxlydmsf","2026-01-13T15:51:47.224Z","2026-06-02T17:09:41.318Z","What Stacking Methods Are Used for Trays? 4 Stacking Methods for Efficient Palletizing","This article demonstrates which stacking methods are used for different applications, where common errors occur, and which stacking method provides the greatest added value.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Stacking methods for plastic trays - Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>The right \u003Cstrong>stacking method\u003C\u002Fstrong> for plastic trays is crucial to avoid transport damage and make processes in production, storage, and logistics more efficient.\u003C\u002Fli>\u003Cli>There are various stacking methods such as \u003Cstrong>undercut stacking\u003C\u002Fstrong>, which is suitable for simple and cost-effective applications, and \u003Cstrong>nub stacking\u003C\u002Fstrong>, which ensures high stability for heavy components and in automated systems.\u003C\u002Fli>\u003Cli>The choice of the appropriate method depends on \u003Cstrong>factors\u003C\u002Fstrong> such as material thickness, product sensitivity, and budget.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ In our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>, you can also test, if you already have 3D data for your tray, which stacking method is best suited for your plastic tray.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Palletising: How to avoid transport damage with the right stacking method\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>If \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">plastic trays\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-is-a-workpiece-carrier\">workpiece carriers\u003C\u002Fa> can be stacked, this has advantages for \u003Cstrong>production, storage and logistics\u003C\u002Fstrong>. \u003C\u002Fp>\u003Cul>\u003Cli>In production, your products are loaded into trays from conveyor belts until the assembled stacks are transported onwards.\u003C\u002Fli>\u003Cli>Free-standing tray stacks do not require any additional boxes or containers as loading aids.\u003C\u002Fli>\u003Cli>Stacking trays save space when storing your products. In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Foptimizing-intralogistics\">intralogistics\u003C\u002Fa>, a stable stacking method ensures safe transport.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">A few key facts about tray stacking methods\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>If trays are to be stacked, this must be taken into account in the design, as additional space is required for stacking. A stackable tray is therefore usually slightly higher than non-stackable models. The tray height when loaded is then made up as follows, for example:\u003C\u002Fp>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:20.43%;\">\u003Cimg style=\"aspect-ratio:273\u002F232;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_24de199cb0.png\" alt=\"Trayhöhe\" width=\"273\" height=\"232\">\u003C\u002Ffigure>\u003Cul>\u003Cli>Height of the components: 65 mm\u003C\u002Fli>\u003Cli>Stacking height: 10 mm\u003C\u002Fli>\u003Cli>Space to the next higher tray: 3 mm\u003C\u002Fli>\u003Cli>Material thickness of the tray (wall thickness): 2 mm\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>= 80 mm loaded Tray height\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:25.65%;\">\u003Cimg style=\"aspect-ratio:436\u002F288;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_5b95b4029d.png\" alt=\"Gesamt-Stapelhöhe\" width=\"436\" height=\"288\">\u003C\u002Ffigure>\u003Ch3>Calculating total stack height\u003C\u002Fh3>\u003Cp>The total stacking height of this example results from the calculated tray height of 80 mm (loaded) and the stacking height of 10 mm per tray added with each tray. If certain outer carton dimensions are specified, it is possible to calculate how many trays fit into a packaging unit.\u003C\u002Fp>\u003Cp>In the formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa>, you can either adapt the tray to a specific carton or directly request a suitable carton for the specified stacking height.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which stacking method is the right one for efficient palletising?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>When selecting the right stacking method for palletising, various points are decisive:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material thickness\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>The required stacking of the tray depends primarily on the material thickness used. The stacking method often depends on whether the tray is used as a disposable or reusable product.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensitivity of the products\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Can the next higher tray stack touch your components or rest on them, or are they touch-sensitive? If you are not allowed to stack over the components, but must leave a few millimetres of clearance to the next higher tray, then the stacking tray must be designed to be self-supporting - this requires robust palletising.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Urgency of the schedule\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Simple stacking techniques, such as undercut stacking, are easier to implement than moving mould parts (a nap stacking) - and therefore shorten the lead time of your first samples.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FStacking_Method_aspects_3e2fc0680d.webp\" alt=\"Stacking Method aspects\">\u003C\u002Fp>\u003Cblockquote>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> With our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>, a suitable stacking technique is recommended based on your component data.\u003C\u002Fp>\u003C\u002Fblockquote>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1672\u002F941;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTray_Gen_Handling_Mockup_2db8160d89.webp\" alt=\"Tray Gen Handling Mockup\" width=\"1672\" height=\"941\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">What exactly is an undercut? And what is it used for when palletising stacking trays?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The most commonly used stacking method in logistics is undercut stacking. An undercut is an inward-facing flange in the tray wall. These are not easy to mould during production, as they have to be removed from the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa> in the opposite direction to the demoulding direction.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:26.31%;\">\u003Cimg style=\"aspect-ratio:400\u002F400;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fguide_74_2_12261286b6.png\" alt=\"Relevanz vom Hinterschnitt beim Stapeln\" width=\"400\" height=\"400\">\u003Cfigcaption>The role of the undercut in the appropriate stacking method\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Advantages of undercut stacking\u003C\u002Fh3>\u003Cp>Despite the more complex manufacturing process, undercut stacking offers several advantages:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Stable stacking:\u003C\u002Fstrong> Trays interlock positively, preventing them from slipping during transport.\u003C\u002Fli>\u003Cli>\u003Cstrong>Cost efficiency:\u003C\u002Fstrong> Additional loading aids (e.g. cardboard boxes) become unnecessary, reducing material and transport costs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Space-saving:\u003C\u002Fstrong> More trays can be accommodated in one packaging unit.\u003C\u002Fli>\u003Cli>\u003Cstrong>Versatile:\u003C\u002Fstrong> Suitable for light to heavy components, depending on the design of the undercuts.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Design of undercuts\u003C\u002Fh3>\u003Cp>The dimensioning of undercuts is based on the requirements of the transported components:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Narrow undercuts:\u003C\u002Fstrong> sufficient for light loads such as cups, plastic parts, or small series.\u003C\u002Fli>\u003Cli>\u003Cstrong>Wide and deep undercuts:\u003C\u002Fstrong> necessary for heavy components such as metal parts, engine or transmission components, so that the load is evenly distributed.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">The price-performance ratio of stacking methods\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>So which techniques are available and which should be used to avoid transport damage? That depends. We provide guide values based on your application or product. What you are primarily interested in when purchasing a tray is often the price - or the price-performance ratio. More complex technologies often have higher tool prices. We explain the background.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">The 4 most common stacking methods at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:2109\u002F1755;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_Modell_Stapelung_png_764a25dac2.webp\" alt=\"3D Tray Modell Stapelung.png\" width=\"2109\" height=\"1755\">\u003C\u002Ffigure>\u003Cp>When palletizing stackable trays and workpiece carriers, there are various methods that are selected depending on weight, material thickness, and area of application. Below we present the four most important stacking techniques.\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Stacking method\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Typical applications\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Advantages\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Disadvantages\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Costs\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Undercut stacking at the edge\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Buckets, cups, small plastic containers\u003C\u002Ftd>\u003Ctd>Cost-effective, can be integrated directly into the tool\u003C\u002Ftd>\u003Ctd>Only suitable for light loads\u003C\u002Ftd>\u003Ctd>Low\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Undercut stacking in the wall\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Single-use trays, small workpiece carriers\u003C\u002Ftd>\u003Ctd>Fast production, inexpensive tools\u003C\u002Ftd>\u003Ctd>Limited load capacity, problematic with heavy parts\u003C\u002Ftd>\u003Ctd>Low–Medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>A\u002FB stacking\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Inlays, packaging trays, empty packaging\u003C\u002Ftd>\u003Ctd>Very good separability, easy handling\u003C\u002Ftd>\u003Ctd>Higher tooling costs due to two variants\u003C\u002Ftd>\u003Ctd>Medium\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Nub stacking with flap tool\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Automation trays, robotics, heavy metal and automotive components\u003C\u002Ftd>\u003Ctd>Highest stability, precise stacking, automation-capable\u003C\u002Ftd>\u003Ctd>Complex tool, longer delivery time\u003C\u002Ftd>\u003Ctd>High\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Undercut stacking at the edge\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>With smaller buckets and tubs, the undercut stacking does not need to be very pronounced due to the low weight. It can therefore be applied directly to the edge. This type of palletising is therefore particularly suitable for containers. Simple undercut stacking can be incorporated into the mould during design and is not cost-intensive.\u003C\u002Fp>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:black;\">\u003Cstrong>Top undercut:\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FHinterschnitt_oben_813af2698e.png\" alt=\"Hinterschnitt oben\">\u003Cfigcaption>Undercut top\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:black;\">\u003Cstrong>Undercut bottom:\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FHinterschnitt_unten_a2a0928b7e.png\" alt=\"Hinterschnitt unten\">\u003Cfigcaption>Undercut bottom\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Undercut stacking in the wall - for disposable trays\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>We have already discussed what undercuts are. As products with a low weight only require a narrow stack, this can be incorporated into the mould without additional features (more on this later). This allows for low-cost moulds and fast production cycles. Just right for disposable trays.\u003C\u002Fp>\u003Ch4>Disadvantages of undercut stacking\u003C\u002Fh4>\u003Cp>The disadvantage, however, is that undercut stacking can naturally reach its limits with thin material. If the load is too heavy and the stacking does not support it, the undercut must either be maximised or the material thickness increased. If this does not help either, dimple stacking must be used (see point 4.).\u003C\u002Fp>\u003Cp>Normal undercut stacking is usually used for transport and storage applications:\u003C\u002Fp>\u003Cul>\u003Cli>Small trays\u003C\u002Fli>\u003Cli>Workpiece carriers with low packing density\u003C\u002Fli>\u003Cli>Workpiece carriers with low weight\u003C\u002Fli>\u003Cli>Low initial thicknesses\u003C\u002Fli>\u003Cli>Disposable trays\u003C\u002Fli>\u003Cli>Lowest possible project costs\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. A\u002FB stacking for inlays and inserts\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A\u002FB stacking is a suitable solution for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">plastic inlays\u003C\u002Fa> and packaging inserts.\u003C\u002Fp>\u003Cul>\u003Cli>With A\u002FB stacking, two different versions, A and B, of the tray are manufactured.\u003C\u002Fli>\u003Cli>The two tray versions are identical, but have offset positioned stacking nubs.\u003C\u002Fli>\u003Cli>During palletizing, an A part is always placed on a B part, so that the nubs always attach at offset positions of the tray and stabilize the parts.\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>The suitable tool for A\u002FB stacking\u003C\u002Fh4>\u003Cp>Theoretically, two different thermoforming tools would be required for A\u002FB stacking. In practice, however, alternatives can be used:\u003C\u002Fp>\u003Cul>\u003Cli>Multi-cavity tools, where 50% A and 50% B trays are produced respectively.\u003C\u002Fli>\u003Cli>Movable modules in a single-cavity tool that are changed after half the quantity.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>These approaches affect the price of A\u002FB stacking, as the tooling effort is higher.\u003C\u002Fp>\u003Ch4>Advantages and areas of application for A\u002FB stacking\u003C\u002Fh4>\u003Cp>A\u002FB stacking is particularly used for empty packaging, i.e., when empty trays are delivered to packaging lines for further processing. Advantages are:\u003C\u002Fp>\u003Cul>\u003Cli>Trays can be easily separated\u003C\u002Fli>\u003Cli>All trays are uniformly aligned\u003C\u002Fli>\u003Cli>Stacks can be processed quickly and efficiently\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Dimple stacking from a flap mould\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>If the stacking has to be very stable, dimple stacking is used for palletising. The stacking trays are supported and stacked by circumferential block segments. If trays contain heavy parts or if precise stacking tolerances of the vertical stack are required (e.g. in a palletiser of an automation system), this is the right technology.\u003C\u002Fp>\u003Ch4>The suitable tool for nub stacking\u003C\u002Fh4>\u003Cp>The circumferential stacking cams are so strongly moulded that they could not be demoulded with a normal tool. For this reason, a flap tool is used:\u003C\u002Fp>\u003Cul>\u003Cli>Horizontal flaps around the tool edge form the block segments.\u003C\u002Fli>\u003Cli>Before demolding, these segments fold to the side so that the tray can be demolded seamlessly.\u003C\u002Fli>\u003Cli>The process requires a more complex tool structure with moving parts.\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Areas of application for nub stacking\u003C\u002Fh4>\u003Cp>This stacking method is more in the premium range, with more cost-intensive tooling construction and longer tool production times. Therefore, flap tool stackings are usually used in higher-value application areas, such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fautomation-of-production-with-trays\">automation\u003C\u002Fa>, where robot palletizing comes into play in addition to manual palletizing.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ More about the selection of the suitable stacking method can be found in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">Design rules for plastic thermoformed parts.\u003C\u002Fa>\u003C\u002Fp>\n\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">These typical mistakes are often made when palletising\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Are you having problems stacking your trays? We discuss the error patterns and their possible causes:\u003C\u002Fp>\u003Cfigure class=\"table\" style=\"width:auto;\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Error pattern\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Cause\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth style=\"padding:4px 8px;\">\u003Cstrong>Solution\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Stack jammed\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Wall draft angles too small\u003C\u002Fli>\u003Cli>Material of the trays adheres to each other\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Increase wall draft angles\u003C\u002Fli>\u003Cli>Use material with anti-blocking properties (e.g. A-PET)\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Trays tilt and slip\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Walls are too thin, become unstable and fork apart → stacking no longer works\u003C\u002Fli>\u003Cli>Stacking surface of the stacking nubs offers too little support surface\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Choose thicker initial thickness\u003C\u002Fli>\u003Cli>Mill stacking nubs wider\u002Fdeeper to increase the support surface\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Stack tilts at an angle\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Stacking not wide enough for stability\u003C\u002Fli>\u003Cli>Insufficient support surface\u003C\u002Fli>\u003Cli>Excessive loading weight or stacking height\u003C\u002Fli>\u003Cli>Stacking technique not adapted to handling\u002Ftransport\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003Ctd>\u003Cul>\u003Cli>Bottom-up-approach\u003Cul>\u003Cli>Choose material with better mechanical properties\u003C\u002Fli>\u003Cli>Tool adjustment with more complex stacking technique\u003C\u002Fli>\u003Cli>Reduce packing density to decrease total weight\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cp>The aim is to prevent jammed and wedged stacks and to achieve the most stable result possible.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion: The right stacking method helps to avoid transport damage\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The right stacking method helps to avoid transport damage by distributing the weight evenly and contributing to the stability of the load. The choice of the right palletizing technique should be tailored to the specific needs to optimize costs and minimize damage.\u003Cbr>Would you like to benefit from this? Simply tell us the stacking height or the number of trays to be stacked when making your request.\u003C\u002Fp>","stacking-methods-for-trays",{"id":435,"documentId":436,"createdAt":437,"updatedAt":438,"publishedAt":85,"locale":10,"title":439,"introduction":440,"content":441,"slug":442},{"id":804,"documentId":805,"createdAt":806,"updatedAt":807,"publishedAt":85,"locale":10,"title":808,"introduction":809,"content":810,"slug":811},359,"pfbv8mi0e4lzuu3yhe46sder","2026-01-13T15:51:49.378Z","2026-06-03T09:38:57.289Z","Surface Finishing for Medical Housings: Function Meets Design","The finishing of medical housing surfaces must meet the highest standards of functionality, hygiene, and design. This blog post will explain how formary uses thermoforming to produce visually appealing and functional medical housings ensuring compliance with regulatory requirements.","\u003Ch2>Surface optimization for thermoformed medical housings – Key facts at a glance\u003C\u002Fh2>\u003Cul>\u003Cli>Modern surfaces for thermoformed medical housings are created through a combination of \u003Cstrong>materials technology\u003C\u002Fstrong> and \u003Cstrong>design \u003C\u002Fstrong>and meet the highest standards of functionality and hygiene.\u003C\u002Fli>\u003Cli>\u003Cstrong>Technical refinements\u003C\u002Fstrong> ensure EMC protection, flame retardancy, and UV resistance for reliable and safe use.\u003C\u002Fli>\u003Cli>\u003Cstrong>Visual optimizations\u003C\u002Fstrong> create CI-compliant designs, thereby improving user-friendliness.\u003C\u002Fli>\u003Cli>\u003Cstrong>Functional refinements\u003C\u002Fstrong> enhance electrical shielding and cleaning resistance and reduce germ contamination.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Configure medical thermoformed part now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What requirements must the surfaces of medical enclosures meet?\u003C\u002Fh2>\u003Cp>The surface treatment of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">medical covers\u003C\u002Fa> must withstand mechanical stress and comply with strict standards for electromagnetic compatibility (EMC), fire safety, and hygiene. In addition, the demands on design and haptics are increasing, as devices are increasingly in the field of vision or in direct contact with patients.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMedizintechnik_Gehaeuse_c095090a55.png\" alt=\"Medical cover for MSOT-Tool\">\u003Cfigcaption>Medical cover for MSOT-Tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>How do technical refinements protect medical devices?\u003C\u002Fh2>\u003Cp>Technical \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\">surface refinements\u003C\u002Fa>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fnachbearbeitungsverfahren\u002Foberflaechenbehandlung\"> \u003C\u002Fa>in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medical technology\u003C\u002Fa> ensure that housings function reliably and safely. These include the following surface treatments:\u003C\u002Fp>\u003Ch3>EMC protection: How is unwanted radiation shielded? \u003C\u002Fh3>\u003Cp>EMC protection (electromagnetic compatibility) uses a conductive inner layer to shield unwanted radiation and protect sensitive electronics including ultrasound devices or ECG systems from emissions and electromagnetic interference. This EMC shielding is achieved through specialized coating processes such as conductive paints, electroplating, or vapor deposition.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FEMV_Abschirmung_85893a197e.webp\" alt=\"EMC as an important criteria for medical covers\">\u003Cfigcaption>EMC as an important criteria for medical covers\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3> \u003C\u002Fh3>\u003Ch3>Flame retardancy: Why is flame resistance so important in medical technology?\u003C\u002Fh3>\u003Cp>Many medical plastic housings must comply with the UL94 V0 classification and self-extinguish within seconds in the event of a fire.\u003C\u002Fp>\u003Ch4>Which plastics offer flame retardancy?\u003C\u002Fh4>\u003Cp>Plastic housings made from material blends such as ABS-PC combinations combine the superior mechanical properties of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">polycarbonate \u003C\u002Fa>with the lower processing temperature and moldability of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS \u003C\u002Fa>and are ideal for flame retardancy. This ensures that safety standards are met with optimal functionality, even for large cladding components.\u003C\u002Fp>\u003Ch3>UV protection: How is the long service life of medical housings guaranteed?\u003C\u002Fh3>\u003Cp>Medical devices are often exposed to intense lighting or direct sunlight, but can be protected by UV-resistant plastics. UV-stabilized plastics such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fasa-plastic\">ASA \u003C\u002Fa>or \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS \u003C\u002Fa>prevent surfaces from yellowing, becoming brittle, or losing their mechanical properties over time. This ensures long-lasting functionality and appearance, even with intensive use.\u003C\u002Fp>\u003Ch2>What are the advantages of optical refinements in medical technology?\u003C\u002Fh2>\u003Cp>The surface of medical cladding components is much more than just a design element. It is crucial for functionality, hygiene, and user-friendliness. Cladding should not only look good but also integrate seamlessly into sterile, functional environments. The advantages:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Ease of use:\u003C\u002Fstrong> Color, finish, and texture influence the ease of use and visual impact of a medical device, especially in clinical environments.\u003C\u002Fli>\u003Cli>\u003Cstrong>Recognition\u003C\u002Fstrong>: CI-compliant color schemes and precise prints ensure recognition and serve as orientation aids.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Direct coloring for series production\u003C\u002Fh3>\u003Cp>For CI-compliant colors and logos on medical technology housings, various color options can already be integrated in the material during production for larger quantities. The desired RAL shade is \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">extruded \u003C\u002Fa>directly into the plastic material using so-called masterbatches. The process is cost-efficient, but requires a minimus material volume (1-5 tons).\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_farbe_01_b74a6e956d.png\" alt=\"Color options for medical housings directly through pre-colored materials or painting\">\u003Cfigcaption>Color options for medical housings directly through pre-colored materials or painting\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>In which cases should paint finishes be used?\u003C\u002Fh3>\u003Cul>\u003Cli>For smaller batch sizes, prototypes, or individual customer requirements, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Foberflaechenbehandlung\u002Fvarnishing\">paint finishes\u003C\u002Fa> offer maximum flexibility even for quantities as low as one.\u003C\u002Fli>\u003Cli>Metallic, matte, or effect paints serve to protect the surface and enhance its appearance, for example by reducing reflections.\u003C\u002Fli>\u003Cli>Film coatings such as polished metal or chrome create attractive designs to achieve a modern, easy-to-clean, and high-quality look.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Further options for surface finishing of medical plastic housings\u003C\u002Fh3>\u003Cp>In addition to painting and coating, the thermoforming process itself offers opportunities for targted surface design. For example, textures and patterns can be engraved directly into the tooling. This allows fine leather-like patterns, grooves, or microtextures to be transferred to the component surface during forming.\u003C\u002Fp>\u003Cp>\u003Cstrong>The result:\u003C\u002Fstrong> glare-free, non-slip, and easy-to-clean surfaces that are ideal for surgical environments or diagnostic workstations.\u003C\u002Fp>\u003Ch2>What advantages do functional finishes offer for medical enclosures?\u003C\u002Fh2>\u003Cp>Beyond design and safety, medical device surfaces must also meet specific functional requirements. These include:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Electroplating\u003C\u002Fstrong>: Electroplated metal layers enhance electrical conductivity and mechanical strength. This is important for enclosure components that require electrical conductivity or must withstand high mechanical loads.\u003C\u002Fli>\u003Cli>\u003Cstrong>Vapor-deposited and uniformly metallized surfaces: \u003C\u002Fstrong>These provide a high-quality, decorative appearance, as is often required for bezels or decorative panels in medical devices.\u003C\u002Fli>\u003Cli>\u003Cstrong>Antimicrobial additives: \u003C\u002Fstrong>Antimicrobial additives such as silver ions, zinc oxide, or copper-based solutions reduce germ contamination.\u003C\u002Fli>\u003Cli>\u003Cstrong>Fluorination & gamma irradiation\u003C\u002Fstrong>: Processes such as fluorination or gamma irradiation specifically alter surface properties.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>However, it is important to note: \u003C\u002Fstrong>Such additives do not replace regular cleaning, which is why resistance to disinfectants is a key criterion in the selection of materials.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FHygieneanforderungen_an_medizinischen_Gehaeusen_02f8c6f1b6.webp\" alt=\"Color options for medical housings directly through pre-colored materials or painting\">\u003Cfigcaption>Color options for medical housings directly through pre-colored materials or painting\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Optimize the surface of your medical device housing now\u003C\u002Fh2>\u003Cp>The surface defines more than just the appearance: it also affects hygiene, safety, functionality, and user experience. With the right materials and processes from formary, you get functional and economically viable solutions for thermoformed components used in medical applications.\u003C\u002Fp>\u003Cp>Request your thermoformed \u003Cstrong>medical housings\u003C\u002Fstrong> directly through the formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator \u003C\u002Fa>and kick-tart your next project.\u003C\u002Fp>","surface-finishing-for-medical-housings",{"id":813,"documentId":814,"createdAt":815,"updatedAt":816,"publishedAt":85,"locale":10,"title":817,"introduction":818,"content":819,"slug":820},376,"yt35yx2a2ob138xd444o1cxl","2026-01-13T15:51:52.616Z","2026-06-15T19:18:02.887Z","Plastic Manufacturing Processes Compared: Thermoforming vs. Injection Molding, 3D Printing, CNC Milling, and Foam","When manufacturing plastic parts, thermoforming is often compared with injection molding, milling, 3D printing, and foam solutions. The decisive factors are speed, cost, design freedom, material requirements, and process reliability. This article highlights the key differences between these processes.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Comparison of plastic manufacturing processes - The most important facts in brief\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Plastic manufacturing processes differ primarily in terms of time-to-market, costs, design freedom, robustness, material diversity, and automatability.\u003C\u002Fli>\u003Cli>\u003Cstrong>Thermoforming\u003C\u002Fstrong> is particularly advantageous for small to medium series and offers short project lead times.\u003C\u002Fli>\u003Cli>\u003Cstrong>Injection molding\u003C\u002Fstrong> is worthwhile for large quantities, but incurs high tooling costs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Milling and 3D printing\u003C\u002Fstrong> are suitable for prototyping, but are expensive in series production.\u003C\u002Fli>\u003Cli>\u003Cstrong>Foam and standard solutions\u003C\u002Fstrong> are cost-effective, but technically limited.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the most important plastic manufacturing processes?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>In plastics engineering, different plastic processes are used depending on the component geometry and quantity.\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Process\u003C\u002Fth>\u003Cth>Category\u003C\u002Fth>\u003Cth>Typical applications\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Thermoforming\u003C\u002Ftd>\u003Ctd>Forming\u003C\u002Ftd>\u003Ctd>Housings, covers, trays, packaging\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Injection molding\u003C\u002Ftd>\u003Ctd>Casting\u003C\u002Ftd>\u003Ctd>Mass-produced products, precision components\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>CNC milling\u003C\u002Ftd>\u003Ctd>Machining\u003C\u002Ftd>\u003Ctd>Precision components, prototypes\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>3D printing\u003C\u002Ftd>\u003Ctd>Additive\u003C\u002Ftd>\u003Ctd>Prototypes, small series, complex geometries\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Foam solutions\u003C\u002Ftd>\u003Ctd>Foaming\u003C\u002Ftd>\u003Ctd>Upholstery, simple packaging\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cp>In plastics engineering, these processes are primarily differentiated according to the molding method, quantity, precision, and material properties.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ In this article, we compare plastic manufacturing processes that are particularly suitable for housings, covers, trays, and functional components. Processes such as extrusion or blow molding are deliberately not covered in depth, as they are primarily used for profiles, films, or hollow bodies without specific geometries. \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">How do key plastic manufacturing processes work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Here is a brief overview of how they work:\u003C\u002Fp>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoforming\u003C\u002Fa>, a plastic sheet is heated and then drawn into a mold. The process is suitable for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">containers\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">housings\u003C\u002Fa>, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fthermoformed-plastic-packaging\">packaging\u003C\u002Fa>, and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">inlays\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FIsometric_view_1_1_30bffb92d9.webp\" alt=\"Isometric view of the thermoforming process\">\u003C\u002Ffigure>\u003Ch3>Injection molding\u003C\u002Fh3>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Finjection-molding-vs-thermoforming\">injection molding\u003C\u002Fa>, plastic is first melted and then injected under pressure into a closed mold. There, the material solidifies through controlled cooling before the mold is opened and the component is removed.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFilling_funnel_1_1_99ee04589a.webp\" alt=\"Injection molding process\">\u003C\u002Ffigure>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Ftrennen\u002Fcnc-milling\">CNC milling\u003C\u002Fa>, a component is carved out of a plastic block by a computer-controlled milling head that precisely removes material along predetermined paths.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_12_1_c0eee05c68.webp\" alt=\"CNC milling process\">\u003C\u002Ffigure>\u003Cp>In \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fthermoforming-vs-3d-printing\">3D printing\u003C\u002Fa>, also known as additive manufacturing, a component is built up layer by layer from plastic.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMaterial_preparation_1_1_ef5d47864c.webp\" alt=\"3D printing process\">\u003C\u002Ffigure>\u003Ch4>Foam and standard solutions\u003C\u002Fh4>\u003Cp>Foam can be produced both chemically and physically. In chemical foaming, typical components such as polyol and isocyanate react with each other, producing CO₂ among other things. This gas causes the mass to foam. In physical foaming, a blowing agent is added which expands or evaporates when heated, thus forming the pore structure.\u003C\u002Fp>\u003Cp>After foaming, the foam block hardens and can then be cut, punched, or CNC-machined. The foam parts produced in this way are particularly suitable for simple packaging, upholstery elements, or standard solutions.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">The top 5 factors to consider when deciding which plastic manufacturing process is best suited to your application\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The processes are compared in five categories that are often decisive when it comes to the production of plastic parts:\u003C\u002Fp>\u003Col>\u003Cli>Time to market\u003C\u002Fli>\u003Cli>Cost structure (for small and medium series)\u003C\u002Fli>\u003Cli>Design freedom & modification effort\u003C\u002Fli>\u003Cli>Mechanical robustness\u003C\u002Fli>\u003Cli>Material selection\u003C\u002Fli>\u003C\u002Fol>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Time-to-market\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Fast development and production start-ups enable you to respond to market requirements. Especially in dynamic markets, a short time-to-market can be crucial for securing competitive advantages or meeting project deadlines.\u003C\u002Fp>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>In the best case scenario, a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">thermoforming project\u003C\u002Fa> can be delivered in less than 6 weeks. This includes 1-2 weeks for creating the design based on the requirements and data in consultation with the company. Once the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fconstruction-data-in-thermoforming\">design data\u003C\u002Fa> has been approved, production of the aluminum series tool begins. Depending on the urgency, this can be done in 3 weeks.\u003C\u002Fp>\u003Cp>As soon as the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">tool\u003C\u002Fa> is ready, it is taken to the thermoforming manufacturer and the first samples are drawn from the series tool and material. Once the series samples have been approved, series production begins. Depending on the quantities and provided that the manufacturer has sufficient capacity, (partial) delivery can take place after just two weeks.\u003C\u002Fp>\u003Ch4>Injection molding\u003C\u002Fh4>\u003Cp>In injection molding, the long tooling times of usually six to twelve weeks lead to a significantly delayed start of series production.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCW_1_2_1_1_0515b9ec9d.webp\" alt=\"Delivery times in injection molding\">\u003C\u002Ffigure>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>Milling and 3D printing are becoming increasingly complex in series production, which means that production times are longer overall. 3D printing is very fast for smaller quantities or prototypes, as no tools are required. This means there are \u003Cstrong>no lead times\u003C\u002Fstrong>. Once the CAD data is available, parts can be manufactured within a few days.\u003C\u002Fp>\u003Cp>For large series, 3D printing or milling is limited due to slower production speeds, poor scalability, and higher material costs.\u003C\u002Fp>\u003Ch4>Foam \u002F Standard solutions\u003C\u002Fh4>\u003Cp>Foam and standard solutions are ready for immediate use, but often do not offer the precision required for technically demanding applications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Cost structure for small and medium series\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In moderate quantities, fixed costs have a direct impact on profitability, as they significantly increase the unit price. Processes with low fixed costs enable more efficient unit costs and reduce the risk of an uneconomical series.\u003C\u002Fp>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>A key cost driver in a thermoforming project is the tooling costs, which represent a one-time investment in the four to five-digit range. These costs are amortized as the number of units increases. Since economies of scale do not apply to the same extent to material costs, the proportion of material costs per thermoformed part increases with increasing quantity and thus becomes the largest cost center.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTotal_cost_share_1_1_079ca23bfa.webp\" alt=\"Cost factors in thermoforming\">\u003C\u002Ffigure>\u003Cp>Compared to other plastic manufacturing processes, thermoforming occupies the “sweet spot” between several hundred and 10,000 parts, as the initial tooling costs are significantly lower than for injection molding and the unit prices are significantly lower than for 3D printing.\u003C\u002Fp>\u003Ch4>Injection molding\u003C\u002Fh4>\u003Cp>Injection molding requires a costly initial investment in the tool, but is more cost-effective in terms of total costs due to low unit prices for quantities of around 10,000 or more. This means that the manufacturing process only pays off for very large series.\u003C\u002Fp>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>3D printing has no initial tooling costs, but due to consistent production times, there is little scope for economies of scale in terms of quantity. Milling also incurs high unit costs, which quickly makes the process uneconomical for small and medium-sized series.\u003C\u002Fp>\u003Ch4>Foam \u002F standard solutions\u003C\u002Fh4>\u003Cp>Foam solutions and standard solutions are cost-effective, but in many cases do not offer sufficient technical durability.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Design freedom & modification effort\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>A manufacturing process that can respond flexibly to product changes, especially in the development phase, and does not make adjustments expensive or time-consuming reduces development risks. This allows updates and optimizations to be implemented without high additional costs.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_15_1_406ba26690.webp\" alt=\"Plastic cover\">\u003C\u002Ffigure>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>Deep drawing offers a high degree of flexibility and allows for adjustments, even for special requirements such as ESD or STANAG compliance.\u003C\u002Fp>\u003Ch4>Injection molding\u003C\u002Fh4>\u003Cp>Injection molding allows for design freedom, but changes to the tool often result in considerable effort and high adjustment costs.\u003C\u002Fp>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>Milling and 3D printing allow for changes. However, milling has geometric limitations, which reduces the scope for design. 3D printing allows for a great deal of creative freedom.\u003C\u002Fp>\u003Ch4>Foam \u002F standard solutions\u003C\u002Fh4>\u003Cp>Foam and standard components offer little scope for customization and are limited to standard shapes.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Mechanical robustness\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Thermoformed parts such as housings or panels must be resilient in real-world use. An unsuitable process will result in components that deform, break, or are unsafe, which can lead to high follow-up costs in assembly and service.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fbehaeltnis_belastung_01_1_1_41d5d7d8e1.webp\" alt=\"Plastic container\">\u003C\u002Ffigure>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>Thanks to adjustable wall thicknesses and the materials used, thermoforming offers high rigidity and excellent mechanical strength.\u003C\u002Fp>\u003Ch4>Injection molding\u003C\u002Fh4>\u003Cp>Injection-molded parts also achieve high strength and are mechanically equivalent to thermoformed parts in terms of robustness.\u003C\u002Fp>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>3D-printed components have significant limitations in terms of mechanical load capacity.\u003C\u002Fp>\u003Ch4>Foam \u002F standard solutions\u003C\u002Fh4>\u003Cp>Foam solutions also have low mechanical load capacity and are therefore usually unsuitable for functional technical applications.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Material selection\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">Materials\u003C\u002Fa> determine both functionality and durability. Requirements such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">ESD protection\u003C\u002Fa>, UV resistance, temperature behavior, or chemical resistance are often crucial to a project. Processes with a limited selection of materials can severely restrict the area of application.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_16_1_5d8c0e1a7b.webp\" alt=\"Plastic flakes\">\u003C\u002Ffigure>\u003Ch4>Plastic Thermoforming\u003C\u002Fh4>\u003Cp>Thermoforming allows for a wide range of materials, including specialized variants such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-workpiece-carriers-for-electronics\">ESD-compatible\u003C\u002Fa> or flame-retardant materials, covering many technical requirements.\u003C\u002Fp>\u003Ch4>Injection molding\u003C\u002Fh4>\u003Cp>Injection molding offers a certain variety of materials, but is limited by process-specific requirements in the selection and combination of plastics.\u003C\u002Fp>\u003Ch4>Milling \u002F 3D printing\u003C\u002Fh4>\u003Cp>The choice of materials for milling and 3D printing is highly dependent on the respective machine, meaning that not all engineering plastics can be used.\u003C\u002Fp>\u003Ch4>Foam \u002F Standard solutions\u003C\u002Fh4>\u003Cp>Foams are difficult to specify and therefore only meet simple material requirements.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic manufacturing processes in tabular comparison:\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages\u003C\u002Fth>\u003Cth>\u003Cstrong>Plastic thermoforming\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Injection molding\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Milling \u002F 3D printing\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Foam \u002F Standard solutions\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Time-to-Market\u003C\u002Ftd>\u003Ctd>quickly achievable, depending on geometry & tooling\u003C\u002Ftd>\u003Ctd>long tooling times (6–12 weeks)\u003C\u002Ftd>\u003Ctd>quick for samples, but time-consuming for series production\u003C\u002Ftd>\u003Ctd>immediately available, but lower precision\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Costs for small\u002Fmedium series\u003C\u002Ftd>\u003Ctd>very efficient, low tooling costs\u003C\u002Ftd>\u003Ctd>high fixed costs, only worthwhile for large series\u003C\u002Ftd>\u003Ctd>high unit costs\u003C\u002Ftd>\u003Ctd>inexpensive, but short service life\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Design freedom & adaptability\u003C\u002Ftd>\u003Ctd>high flexibility (also for ESD, STANAG, etc.)\u003C\u002Ftd>\u003Ctd>high adaptation costs\u003C\u002Ftd>\u003Ctd>geometrically limited (milling) \u002F very free (3D printing)\u003C\u002Ftd>\u003Ctd>hardly customizable\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Mechanical robustness\u003C\u002Ftd>\u003Ctd>high rigidity due to wall thickness adjustment\u003C\u002Ftd>\u003Ctd>high strength due to compacted plastic melt\u003C\u002Ftd>\u003Ctd>limited with 3D printing; CNC robust\u003C\u002Ftd>\u003Ctd>low stability\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Material selection (e.g., ESD, PC, STANAG)\u003C\u002Ftd>\u003Ctd>wide selection, including specialized materials\u003C\u002Ftd>\u003Ctd>limited by process-related requirements\u003C\u002Ftd>\u003Ctd>depends on machine & process\u003C\u002Ftd>\u003Ctd>hardly specifiable\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which plastic manufacturing process is right for my project?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The choice of the appropriate process depends largely on the number of units, the type of component, and the cost requirements. A quick basis for decision-making:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Recommendation of the appropriate plastic process based on number of units\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Quantity\u003C\u002Fth>\u003Cth>Recommended plastic process\u003C\u002Fth>\u003Cth>\u003Cstrong>Why?\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>1–20 pieces\u003C\u002Ftd>\u003Ctd>3D printing or CNC milling\u003C\u002Ftd>\u003Ctd>Maximum flexibility, no tooling costs, ideal for prototypes or functional samples.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>20–500 pieces\u003C\u002Ftd>\u003Ctd>Thermoforming\u003C\u002Ftd>\u003Ctd>Very low tooling costs, fast implementation, economical for small series.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>10,000 - 100,000 pieces\u003C\u002Ftd>\u003Ctd>Thermoforming or injection molding (to be considered individually)\u003C\u002Ftd>\u003Ctd>Thermoforming is most cost-effective for thin-walled, large components; injection molding is useful for high precision\u002Fdetail requirements.\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>100,000+ pieces\u003C\u002Ftd>\u003Ctd>typically injection molding (or thermoforming with appropriate tools)\u003C\u002Ftd>\u003Ctd>High tooling costs are offset by minimal unit costs.\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Select the right manufacturing process for your project now\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Choosing the right process determines costs, speed, and technical performance. With formary, you not only receive high-quality products, but also support in selecting materials, surfaces, and the optimal process.\u003C\u002Fp>\u003Cp>On request, we can also check whether a combination of several plastic manufacturing processes makes sense—for example, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Frapid-prototyping-in-thermoforming\">prototyping\u003C\u002Fa> using 3D printing and subsequent series production using thermoforming. Start now with your inquiry via the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">formary configurator\u003C\u002Fa> and realize your next project quickly and efficiently.\u003C\u002Fp>","plastic-manufacturing-processes-compared",{"id":822,"documentId":823,"createdAt":824,"updatedAt":825,"publishedAt":85,"locale":10,"title":826,"introduction":827,"content":828,"slug":829},358,"p7xknhhak0ukuf45xqtqknjf","2026-01-13T15:51:49.205Z","2026-06-03T09:41:41.816Z","Painting Plastic – What to Consider When Coating Thermoplastics","Painting thermoformed plastic parts is an option not only to enhance their aesthetic appeal but also to improve their durability and resistance. In this blog post, we will explore the key aspects to consider when painting thermoformed plastic parts.","\u003Ch2>Painting plastic - The essentials in brief\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Aesthetics and protection:\u003C\u002Fstrong> Painting not only gives plastic parts a visually high-quality surface with special effects (e.g. high gloss, metallic), but also a protective layer against environmental influences such as UV radiation and chemicals.\u003C\u002Fli>\u003Cli>\u003Cstrong>Flexibility compared to colored material:\u003C\u002Fstrong> Painting is often preferred over using colored semi-finished products to avoid minimum order quantities that occur during the extrusion of special color tones. It is also the only method to realize multi-colored designs on a single component.\u003C\u002Fli>\u003Cli>\u003Cstrong>Importance of preparation:\u003C\u002Fstrong> A successful and durable paint finish depends crucially on proper surface pretreatment, as plastics naturally have lower adhesion for paints. For this purpose, special 2K-PUR paints and cleaning processes such as CO₂ or plasma cleaning are used.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request thermoformed part with plastic painting now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What advantages does painting plastic offer for thermoformed parts?\u003C\u002Fh2>\u003Cp>Thermoformed parts can either be manufactured from already colored semi-finished products or painted afterwards. The latter offers a number of advantages that go beyond pure coloring.\u003C\u002Fp>\u003Cfigure class=\"image image-style-side\">\u003Cimg style=\"aspect-ratio:853\u002F431;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTray_mit_Farbstreifen_a0b7ab35d4.png\" alt=\"Kunststofftray mit Farbstreifen.png\" width=\"853\" height=\"431\">\u003C\u002Ffigure>\u003Ch3>1. Painting plastic for aesthetics and brand identity\u003C\u002Fh3>\u003Cp>Painting your plastic thermoformed parts strengthens brand identity and improves aesthetics. This \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fsurface-finishing-for-medical-housings\">surface finishing\u003C\u002Fa> makes your product appear directly higher quality.\u003C\u002Fp>\u003Ch4>Painting options\u003C\u002Fh4>\u003Cul>\u003Cli>High gloss\u003C\u002Fli>\u003Cli>Metallic effects\u003C\u002Fli>\u003Cli>Matting or structured paint finish\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Furthermore, full-surface or partial coloring, different colors or color gradients in all RAL color tones is also possible.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ To customize your plastic thermoformed part with your CI or other important core information, you can also print on it. More on this under \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fprinting-on-plastic-parts\">printing on plastic parts.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>2. Painting plastic for protection against environmental influences\u003C\u002Fh3>\u003Cp>The paint coating forms a protective layer that protects thermoformed parts from environmental influences such as UV radiation, moisture and chemicals. Painting plastic thus contributes to a longer service life of the parts and increases the throughput cycles of your process chain.\u003C\u002Fp>\u003Ch3>3. Painting plastic for improved cleaning and care\u003C\u002Fh3>\u003Cp>Painted plastic thermoformed parts are easier to clean and maintain. The smooth surface prevents dirt from settling and facilitates maintenance. You can find out how to clean your trays in the article \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fhow-to-clean-trays\">cleaning trays\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image_resized image-style-side\" style=\"width:28.97%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FInlay_in_gruen_1_36e6f5b9e0.jpg\" alt=\"Inlay in grün (1).jpg\" width=\"640\" height=\"640\">\u003C\u002Ffigure>\u003Ch2>Why paint plastic instead of colored semi-finished products for plastic parts?\u003C\u002Fh2>\u003Cp>As mentioned above, coloring can also be achieved by procuring an appropriate semi-finished product, i.e. the thermoforming film or sheet, which is already colored in the desired RAL tone.\u003Cbr>However, different circumstances and requirements may favor plastic painting afterwards to achieve the desired surface finish. In these cases, the procurement of a colored semi-finished product is usually avoided and painting of the thermoformed parts is used:\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:19.44%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FLackiertes_Kunststoffgehaeuse_in_rot_6d1deef253.jpg\" alt=\"Kunststoff lackieren - Kunststoffgehäuse in rot\">\u003Cfigcaption>Plastic housing in orange\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Minimum order quantities (MOQ)\u003C\u002Fh3>\u003Cp>Special (RAL) color tones are extruded customer-specifically. Based on the requirements and the specific production run, most material manufacturers require minimum order quantities of the material, which are often too high to commission an extrusion of the semi-finished product for a specific product or order.\u003C\u002Fp>\u003Ch3>Multi-colored parts\u003C\u002Fh3>\u003Cp>If a thermoformed part is desired to be multi-colored, this cannot be solved by a colored, extruded semi-finished product. By default, only the application of individual color stripes for product identification is an option here. For more complex coloring, painting plastic is chosen as a solution, among others.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Which Plastics Can Be Painted?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Not all \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> can be painted equally well, as they have lower paint adhesion. 2K-PUR paints (polyurethane paints), which are specially developed for plastics, are well suited. Below you can see an overview of the paintability of plastics.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics That Are Easy to Paint:\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa> (Acrylonitrile Butadiene Styrene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa> (Polycarbonate)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpmma-plastic\">PMMA\u003C\u002Fa> (Polymethyl Methacrylate)\u003C\u002Fli>\u003Cli>PA (Polyamide)\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics That Are Difficult to Paint:\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PE\u003C\u002Fa> (Polyethylene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa> (Polypropylene)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpvc-plastic\">PVC\u003C\u002Fa> (Polyvinyl Chloride)\u003C\u002Fli>\u003Cli>Other elastic plastics\u003C\u002Fli>\u003C\u002Ful>\u003Cp>More information about materials and their properties can be found in the webinar \u003Ca href=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=HhU0eK7A1ag\">thermoplastic plastics\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=HhU0eK7A1ag\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Ch2>What you should do before painting plastic\u003C\u002Fh2>\u003Cp>To improve the adhesion of paints on plastics, special pretreatments are often carried out. This can include, for example, the use of adhesion promoters, primers or other chemical treatments to increase the surface energy from a chemical perspective and improve adhesion.\u003Cbr>It is important to consider the compatibility between the plastic material and the selected paint system to ensure successful plastic painting. There are several methods for pretreatment, which are explained in more detail below.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:54.04%;\">\u003Cimg style=\"aspect-ratio:640\u002F319;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoff_lackieren_Lackierverfahren_e394423dfb.jpg\" alt=\"Kunststoff lackieren - Verfahren\" width=\"640\" height=\"319\">\u003C\u002Ffigure>\u003Ch3>Surface cleaning\u003C\u002Fh3>\u003Cp>Painting plastic requires a carefully cleaned surface that is free from contamination. This can be pretreated in various ways with the following cleaning methods:\u003C\u002Fp>\u003Ch3>CO₂ cleaning\u003C\u002Fh3>\u003Cp>The plastic part is cleaned using compressed carbon dioxide. The CO₂ is used in a blasting process to remove contaminants.\u003C\u002Fp>\u003Ch3>Steam cleaning\u003C\u002Fh3>\u003Cp>In steam cleaning, plastic parts are cleaned with hot steam. This environmentally friendly cleaning process leaves no residue on the parts.\u003C\u002Fp>\u003Ch3>Flame treatment\u003C\u002Fh3>\u003Cp>Flame treatment manages to remove contaminants through targeted application of \u003Cstrong>heat\u003C\u002Fstrong>. This method leaves no residue and contributes to effective surface cleaning.\u003C\u002Fp>\u003Ch3>Low-pressure plasma system\u003C\u002Fh3>\u003Cp>In low-pressure plasma systems, plastic parts are cleaned by applying ionized gas. The generated plasma interacts with the surfaces, effectively removing contaminants without leaving residue.\u003C\u002Fp>\u003Ch2>Painting processes for thermoplastics\u003C\u002Fh2>\u003Cp>After thorough cleaning of the plastic parts, the decision follows: Should the painting be done manually or automatically? Today, masking-free painting processes are frequently used. These enable precise coating without the need to laboriously cover certain areas. The choice of process depends on volume, component geometry and process requirements. In overview:\u003C\u002Fp>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:34.37%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FRoter_Kunststoffbehaelter_Kunststoff_lackieren_65a6765195.jpg\" alt=\"Kunststoff lackieren mit roter Farbe auf der Kunststoffwanne\" width=\"640\" height=\"640\">\u003Cfigcaption>Red plastic container\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Robot-based painting\u003C\u002Fh3>\u003Cp>Industrial robots perform precise painting movements and can take into account complex geometries of the plastic parts, ensuring uniform and reliable painting without masking.\u003C\u002Fp>\u003Ch3>Automated painting lines\u003C\u002Fh3>\u003Cp>Conveyor belts or automated transport systems guide the plastic parts through the painting process, enabling continuous and efficient series painting.\u003C\u002Fp>\u003Ch3>Spray painting\u003C\u002Fh3>\u003Cp>Here, the paint is applied to the surface of the plastic parts in the form of fine droplets using compressed air or electrostatics to ensure uniform distribution of the paint material.\u003C\u002Fp>\u003Ch3>Dip painting\u003C\u002Fh3>\u003Cp>The plastic parts are dipped into a paint tank, resulting in uniform painting. After the dipping process, the excess is dripped or blown off.\u003C\u002Fp>\u003Ch3>Drying phase after painting\u003C\u002Fh3>\u003Cp>After each process, \u003Cstrong>drying\u003C\u002Fstrong> follows to harden the surface. This creates a resistant, durable and visually high-quality paint finish.\u003C\u002Fp>\u003Ch2>Application areas of painted plastic parts\u003C\u002Fh2>\u003Cp>Painted thermoplastics are used in many industries:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">Automotive industry\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">Electronics manufacturing\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Frobotics\">Robotics\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Faerospace-defense\">Aerospace & defense\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fagriculture-horticulture\">Agriculture & horticulture\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Findustrial-solutions\">Industrial manufacturing\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>Painting plastic for your thermoformed parts - A conclusion\u003C\u002Fh2>\u003Cp>Plastic painting of thermoformed parts offers numerous advantages in terms of aesthetics, protection and care. By considering the material properties and suitable painting techniques, high-quality results can be achieved.\u003Cbr>However, this only works with the right preparation. Questions about the optimal coloring of your thermoformed part? Feel free to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">contact us\u003C\u002Fa> by email or call directly \u003Cstrong>Tel:+4971919525170.\u003C\u002Fstrong>\u003C\u002Fp>","painting-plastic",{"id":174,"documentId":831,"createdAt":832,"updatedAt":833,"publishedAt":85,"locale":10,"title":834,"introduction":835,"content":836,"slug":837},"xsro6vdvev5vn6a30t75xxs4","2026-01-26T09:11:12.014Z","2026-06-16T08:48:14.150Z","B2B Platforms in Plastics Processing: Functions, Processes & Decision Criteria 2026","In 2026, B2B platforms are evolving from pure procurement tools into central control elements of industrial value creation. This shift is especially pronounced in plastics processing, a field characterized by complex materials, highly variant components, and demanding quality requirements. ","\u003Ch2>B2B Platforms in Plastics Processing 2026 – Key Takeaways\u003C\u002Fh2>\u003Cul>\u003Cli>By 2026, B2B platforms will prevail that seamlessly connect RFQ (Request for Quotation), engineering, quality, and delivery capability into one end-to-end process.\u003C\u002Fli>\u003Cli>Successful B2B platforms in Germany do not position themselves as pure marketplaces but as 100% responsible partners.\u003C\u002Fli>\u003Cli>Manufacturing platforms become the operational backbone between purchasing, engineering, and production.\u003C\u002Fli>\u003Cli>For plastic components in Germany, what counts is: clear responsibility, reproducible quality, and reliable delivery schedules.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>What Are Digital B2B Platforms in an Industrial Context?\u003C\u002Fh2>\u003Cp>In an industrial context, a B2B platform is not a “portal with a list of suppliers,” but rather a process system that standardizes interaction and transactions between multiple parties: inquiry, technical clarification, quotation, order placement, quality assurance, logistics, and documentation.\u003C\u002Fp>\u003Ch3>Types of B2B Platforms\u003C\u002Fh3>\u003Col>\u003Cli>\u003Cstrong>Marketplace platforms:\u003C\u002Fstrong> connect suppliers and buyers, with responsibility usually remaining with the two parties.\u003C\u002Fli>\u003Cli>\u003Cstrong>Intermediary platforms:\u003C\u002Fstrong> coordinate processes; responsibility and liability are deliberately limited.\u003C\u002Fli>\u003Cli>\u003Cstrong>Managed manufacturing platforms:\u003C\u002Fstrong> projects, quality, and schedules are centrally managed digitally. Production takes place within a partner network — responsibility lies with the platform operator.\u003C\u002Fli>\u003C\u002Fol>\u003Cp>Especially for thermoformed plastic parts, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">functional trays,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-covers\">housings,\u003C\u002Fa> or serial components, model 3 is decisive. formary deliberately positions itself as the responsible contractual partner for both customer and manufacturer, not as a pure order broker.\u003C\u002Fp>\u003Ch4>Overview: Comparison of Three Platform Models\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Model\u003C\u002Fth>\u003Cth>Characteristics\u003C\u002Fth>\u003Cth>Risk\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Marketplace\u003C\u002Ftd>\u003Ctd>Contact brokerage, minimal process governance\u003C\u002Ftd>\u003Ctd>High variance, unclear quality\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Intermediary\u003C\u002Ftd>\u003Ctd>Process coordination, limited liability\u003C\u002Ftd>\u003Ctd>Responsibility remains fragmented\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Managed manufacturing platform\u003C\u002Ftd>\u003Ctd>Central project, quality, and schedule ownership\u003C\u002Ftd>\u003Ctd>Higher demands on the platform\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:31.91%;\">\u003Cimg style=\"aspect-ratio:150\u002F150;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fillustration_production_5146b1bc6c.svg\" alt=\"Schaubild von Produktionsprozessen in der Kunststoffverarbeitung\" width=\"150\" height=\"150\">\u003C\u002Ffigure>\u003Ch2>Smart Manufacturing: What Do B2B Platforms Actually Deliver in 2026?\u003C\u002Fh2>\u003Cp>Data-driven platforms act as the \u003Cstrong>operational backbone\u003C\u002Fstrong> for:\u003C\u002Fp>\u003Cul>\u003Cli>higher production utilization\u003C\u002Fli>\u003Cli>better planning reliability\u003C\u002Fli>\u003Cli>faster responsiveness\u003C\u002Fli>\u003Cli>fewer media discontinuities\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Digital platforms consolidate these effects from inquiry and design through to production.\u003C\u002Fp>\u003Ch3>1) Process APIs Between Purchasing, Engineering & Manufacturing\u003C\u002Fh3>\u003Cp>B2B buyers still work across countless channels (email, phone calls, approval PDFs, Excel bills of materials, etc.), resulting in a poor purchasing experience. This is precisely why platforms in 2026 become the connective process interface between purchasing, engineering, and production. Digital configurators, structured RFQs, and consistent documentation replace fragmented email, Excel, and PDF processes, enabling an end-to-end, media-break-free flow from inquiry to implementation.\u003C\u002Fp>\u003Ch3>2) Decision Capability Instead of Price Comparison\u003C\u002Fh3>\u003Cp>Competition is increasingly no longer decided by the lowest price, but by the best data-based decision foundation. Platforms do not merely provide supplier prices; they make technical and economic implications transparent, for example through DfM analyses or alternative materials and processes. This makes it clear early on which option best balances cost, risk, and feasibility.\u003C\u002Fp>\u003Ch3>3) Standardized Quality Management\u003C\u002Fh3>\u003Cp>In 2026, quality is systematically embedded in the process. B2B platforms establish defined approval steps, versioned data states, and traceable decision paths. Supplier audits are standardized and centrally handled by the platform provider.\u003C\u002Fp>\u003Ch3>4) Traceability as the Default\u003C\u002Fh3>\u003Cp>Traceability evolves from an optional feature to a standard. Manufacturing platforms ensure that CAD versions, approvals, tool status, and relevant quality information are clearly linked. Transparency across the entire lifecycle becomes the norm.\u003C\u002Fp>\u003Ch3>5) Central Customer Portal\u003C\u002Fh3>\u003Cp>Instead of scattered communication, the customer portal becomes the central workspace. Project status, changes, approvals, and communication are bundled in one place.\u003C\u002Fp>\u003Ch3>6) Digital Engineering Tools\u003C\u002Fh3>\u003Cp>Early concepts, layouts, and technical evaluations accelerate decisions and reduce costly and time-intensive iteration loops.\u003C\u002Fp>\u003Ch3>7) Responsibility Instead of Mediation\u003C\u002Fh3>\u003Cp>By 2026, platform performance is increasingly judged by responsibility. Rather than simple mediation, platforms assume the role of a digital manufacturer across the entire lifecycle — from technical clarification and quality assurance to scheduling and serial production.\u003C\u002Fp>\u003Ch2>How Does formary Implement These Requirements as a B2B Manufacturing Platform?\u003C\u002Fh2>\u003Cp>formary implements these general requirements specifically for plastics processing and positions itself not as a marketplace, but as the responsible single point of contact between purchasing, engineering, and manufacturing.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1455\u002F828;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FErster_Schritt_im_Konfigurator_in_der_englischen_Version_b8485f896f.webp\" alt=\"View of first step in the configurator\" width=\"1455\" height=\"828\">\u003C\u002Ffigure>\u003Cp>At formary, projects start with a structured inquiry using the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator,\u003C\u002Fa> which is specifically designed for thermoformed plastic parts, trays, housings, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-inlays\">inlays,\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Fplastic-containers\">containers.\u003C\u002Fa> Among other things, the following are captured:\u003C\u002Fp>\u003Cul>\u003Cli>3D and 2D data\u003C\u002Fli>\u003Cli>dimensions\u003C\u002Fli>\u003Cli>planned quantities and annual volumes\u003C\u002Fli>\u003Cli>functional requirements\u003C\u002Fli>\u003Cli>aesthetic requirements\u003C\u002Fli>\u003Cli>specific plastic requirements (fire resistance, chemical resistance, etc.)\u003C\u002Fli>\u003Cli>material selection (e.g., \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-g-plastic\">PET-G,\u003C\u002Fa> etc.)\u003C\u002Fli>\u003Cli>and additional factors\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The goal is a robust technical and economic decision basis.\u003C\u002Fp>\u003Ch3>DfM & Engineering as an Integrated Process\u003C\u002Fh3>\u003Cp>formary integrates manufacturing-oriented design early on through a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis.\u003C\u002Fa> This technical clarification takes place before quotation and is documented so that decisions remain traceable.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDf_M_Analyse_Software_Mockup_5e3c27edb2.webp\" alt=\"DfM-Analyse Software Mockup\">\u003C\u002Fp>\u003Cp>With the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">\u003Cu>3D Tray Generator,\u003C\u002Fu>\u003C\u002Fa> tray concepts can be created by uploading component data, enabling companies to start internal planning at an early stage.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_Generator_Mockup_Feature_Fokus_f1c7439336.webp\" alt=\"3D Tray Generator Mockup_Feature Fokus\">\u003C\u002Fp>\u003Ch3>Quotation Logic with Technical Safeguards\u003C\u002Fh3>\u003Cp>Quotations at formary are based on structured costing models that consider, among other factors:\u003C\u002Fp>\u003Cul>\u003Cli>material usage\u003C\u002Fli>\u003Cli>tooling concept and design\u003C\u002Fli>\u003Cli>machine selection\u003C\u002Fli>\u003Cli>setup and cycle times\u003C\u002Fli>\u003Cli>post-processing and quality assurance\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp> ℹ️ In our blog post \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002F5-levers-formary-uses-to-reduce-thermoforming-costs\">5 Levers formary Uses to Reduce Thermoforming Costs\u003C\u002Fa>, you can learn how to achieve the optimal balance of cost and quality using the formary platform.  \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>Serial Approval & Traceability\u003C\u002Fh3>\u003Cp>After order placement, all relevant data states are centrally consolidated in the formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Faccount\u002Flogin\">customer portal.\u003C\u002Fa> The \u003Cstrong>customer portal\u003C\u002Fstrong> provides full transparency regarding:\u003C\u002Fp>\u003Cul>\u003Cli>status tracking\u003C\u002Fli>\u003Cli>specification changes\u003C\u002Fli>\u003Cli>direct communication with the project manager\u003C\u002Fli>\u003Cli>fast approvals\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This establishes the foundation for traceability, reproducible quality, and long-term serial production.\u003C\u002Fp>\u003Ch3>End-to-End Responsibility in Project Planning\u003C\u002Fh3>\u003Cp>Within \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">project planning\u003C\u002Fa>, formary assumes full responsibility for:\u003C\u002Fp>\u003Cul>\u003Cli>technical clarification\u003C\u002Fli>\u003Cli>quality assurance\u003C\u002Fli>\u003Cli>schedule and capacity planning\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Manufacturing partners are integrated into the network, but overall project responsibility remains centrally managed.\u003C\u002Fp>\u003Ch2>Opportunities and Risks of Online Manufacturing Platforms\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSchaubild_von_produzierenden_Unternehmen_f4e1bf7ed2.webp\" alt=\"This image shows what manufacturing processes entail\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>Opportunities\u003C\u002Fh3>\u003Cul>\u003Cli>reduced time-to-market\u003C\u002Fli>\u003Cli>improved planning reliability\u003C\u002Fli>\u003Cli>greater transparency\u003C\u002Fli>\u003Cli>lower coordination costs\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Risks\u003C\u002Fh3>\u003Cul>\u003Cli>unclear responsibility\u003C\u002Fli>\u003Cli>missing DfM validation\u003C\u002Fli>\u003Cli>quality responsibility shifted to partners without a system\u003C\u002Fli>\u003Cli>lack of traceability\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The decisive factor is not platform size, but process quality.\u003C\u002Fp>\u003Ch4>Decision Support: Platform Checklist 2026\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Criterion\u003C\u002Fth>\u003Cth>Good Answer in 2026\u003C\u002Fth>\u003Cth>Warning Sign\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Technical clarification\u003C\u002Ftd>\u003Ctd>DfM review, clear specification logic\u003C\u002Ftd>\u003Ctd>“Just send a drawing”\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Quotation quality\u003C\u002Ftd>\u003Ctd>Transparent pricing logic, documented assumptions\u003C\u002Ftd>\u003Ctd>Price without parameters or assumptions\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Quality\u003C\u002Ftd>\u003Ctd>Defined inspection and approval processes, traceable documentation\u003C\u002Ftd>\u003Ctd>Quality “handled by partner” without a system\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Delivery capability\u003C\u002Ftd>\u003Ctd>Reliable capacity and schedule commitments\u003C\u002Ftd>\u003Ctd>Non-binding lead times\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Data & evidence\u003C\u002Ftd>\u003Ctd>Exportable documentation bundles, traceability\u003C\u002Ftd>\u003Ctd>PDFs via email, no versioning\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Responsibility\u003C\u002Ftd>\u003Ctd>Single point of contact\u003C\u002Ftd>\u003Ctd>“We only mediate”\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Platform Economy in Germany 2026 – Conclusion\u003C\u002Fh2>\u003Cp>In 2026, B2B platforms in plastics processing will primarily do one thing: standardize execution — technically, operationally, qualitatively, and data-driven. Platforms like formary already demonstrate what this future looks like today:\u003C\u002Fp>\u003Cul>\u003Cli>one system instead of many isolated solutions\u003C\u002Fli>\u003Cli>smart manufacturing instead of fragmented processes\u003C\u002Fli>\u003Cli>decision capability instead of pure quotation handling\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cstrong>formary\u003C\u002Fstrong> is not a marketplace, but a managed digital manufacturing platform — with a clear focus on manufacturing-oriented design, reliable quotations, and reproducible quality for thermoformed plastic components.\u003C\u002Fp>","b2b-platforms-in-plastics-processing",{"id":839,"documentId":840,"createdAt":841,"updatedAt":842,"publishedAt":85,"locale":10,"title":843,"introduction":844,"content":845,"slug":846},470,"qxno01sf2rt8pqai32egt8vd","2026-01-26T14:12:29.136Z","2026-05-27T13:31:25.573Z","Tool Transfer in Thermoforming: A Guide for Existing Thermoformed Tools","Tool transfer in thermoforming makes it possible to continue using existing tools and to keep producing components without unnecessary costs or delays. In this article, you will learn about the benefits this offers, which information is required, and how formary efficiently supports the entire process.","\u003Ch2>Tool Transfer in Plastic Thermoforming – Key Facts in Brief\u003C\u002Fh2>\u003Cul>\u003Cli>A \u003Cstrong>tool transfer\u003C\u002Fstrong> allows existing thermoforming tools to be reused without the need to manufacture new tooling.\u003C\u002Fli>\u003Cli>Companies \u003Cstrong>save \u003C\u002Fstrong>costs and time while reducing project risks and waste.\u003C\u002Fli>\u003Cli>For a smooth transfer, key \u003Cstrong>technical data \u003C\u002Fstrong>must be available and clarified in advance.\u003C\u002Fli>\u003Cli>formary handles the\u003Cstrong> technical assessment \u003C\u002Fstrong>and ensures efficient integration into the serial production process.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Would you like to transfer your tool? \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">Contact us!\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch3>What Does Tool Transfer in Thermoforming Mean?\u003C\u002Fh3>\u003Cp>Tool transfer, often also referred to as tool relocation, describes the transfer of an existing \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool \u003C\u002Fa>to a new manufacturer in order to continue production there without creating a new tool.\u003C\u002Fp>\u003Cp>A prerequisite for a tool transfer to a new thermoforming supplier is that the tool is owned by the customer. This is typically the case if the tooling costs were listed separately in the original quotation and not allocated proportionally to part prices. In this situation, the tool belongs to the customer and can be withdrawn from the current manufacturer and relocated to another producer at any time.\u003C\u002Fp>\u003Cp>\u003Cstrong>The aim of tool transfer:\u003C\u002Fstrong> to continue using existing tools efficiently and to maintain production without interruption.\u003C\u002Fp>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FIsometric_View_d4a648ce55.webp\" alt=\"Isometric View of a thermoforming tool\">\u003C\u002Fp>\u003Ch3>When Does a Tool Transfer in Thermoforming Make Sense?\u003C\u002Fh3>\u003Cp>Relocating thermoforming tools is particularly beneficial when an existing thermoforming tool is still fully functional and capable of production. By continuing to use an existing tool instead of building a completely new one, companies can keep using their thermoformed tools economically, even if contract manufacturing with the current supplier is no longer desired.\u003C\u002Fp>\u003Cp>Once a tool has been manufactured, it can typically be used for production over a very long service life. When aluminum tools are used and regular maintenance is carried out, production volumes of tens or even hundreds of thousands of cycles are common.\u003C\u002Fp>\u003Ch2>Why Are Thermoforming Tools Typically Transferred?\u003C\u002Fh2>\u003Cp>In industrial practice, the relocation of existing thermoforming tools can be a strategically important step. Companies sourcing plastic thermoformed parts usually relocate tools to ensure production continuity, control costs, and minimize risks.\u003C\u002Fp>\u003Ch3>Typical reasons for tool relocation include:\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>(Impending) insolvency or business closure of the current supplier\u003C\u002Fstrong>\u003Cbr>To avoid production stoppages, tools are transferred early to an alternative manufacturer.\u003C\u002Fli>\u003Cli>\u003Cstrong>Quality issues within the existing supply chain\u003C\u002Fstrong>\u003Cbr>Repeated deviations in dimensional accuracy, surface quality, or material processing make a change of supplier necessary.\u003C\u002Fli>\u003Cli>\u003Cstrong>Increasing cost pressure\u003C\u002Fstrong>\u003Cbr>Changes in pricing structures, energy costs, or labor costs may require a more economical production setup.\u003C\u002Fli>\u003Cli>\u003Cstrong>Risk management and supply chain security\u003C\u002Fstrong>\u003Cbr>Tool relocations are a proven means of reducing dependencies and increasing supply reliability.\u003C\u002Fli>\u003Cli>\u003Cstrong>Tool damage or limited production capability\u003C\u002Fstrong>\u003Cbr>When maintenance, repairs, or modifications can no longer be carried out reliably by the current supplier.\u003C\u002Fli>\u003Cli>\u003Cstrong>Prevention of production downtime\u003C\u002Fstrong>\u003Cbr>Early relocation helps prevent unplanned stoppages in series products with long life cycles.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Advantages of taking over existing thermoforming tools:\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cstrong>Cost efficiency:\u003C\u002Fstrong> Avoiding new tool costs leads to significant cost savings.\u003C\u002Fli>\u003Cli>\u003Cstrong>Fast start of series production:\u003C\u002Fstrong> Since the tool already exists and has been tested, sampling, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Frapid-prototyping-in-thermoforming\">prototyping\u003C\u002Fa>, and production can begin much earlier.\u003C\u002Fli>\u003Cli>\u003Cstrong>High process reliability:\u003C\u002Fstrong> Geometries and material behavior have already been validated, ensuring functionality and requiring only minimal adjustments.\u003C\u002Fli>\u003Cli>\u003Cstrong>Sustainability:\u003C\u002Fstrong> The service life of the tool is extended and unnecessary new construction is avoided.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>Guide: How Tool Transfer Works with formary\u003C\u002Fh2>\u003Cp>To ensure that a thermoforming tool can be seamlessly transferred to a new manufacturer, all technical details must be clarified in advance. formary reviews this information to ensure compatibility and a fast start to serial production.\u003C\u002Fp>\u003Cp>The following questions should therefore be clarified upfront:\u003C\u002Fp>\u003Ch3>1. CAD Data\u003C\u002Fh3>\u003Cul>\u003Cli>Are CAD data for the tool available?\u003C\u002Fli>\u003Cli>Can 2D or 3D files be provided?\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:474\u002F384;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_18_1_0bd8cce6ce.webp\" alt=\"Tiefziehteil CAD-Daten\" width=\"474\" height=\"384\">\u003C\u002Ffigure>\u003Ch3>2. Photos & Visual Inspection\u003C\u002Fh3>\u003Cul>\u003Cli>Are images of the tools available?\u003C\u002Fli>\u003Cli>Are the vacuum ports visible?\u003C\u002Fli>\u003Cli>What is the general condition?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Photos provide a quick indication of whether the tool, frame, and surfaces are intact.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1280\u002F720;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehwerkzeug_aus_Aluminium_1_093e9a4690.webp\" alt=\"Tiefziehwerkzeug aus Aluminium\" width=\"1280\" height=\"720\">\u003C\u002Ffigure>\u003Ch3>3. Dimensions\u003C\u002Fh3>\u003Cul>\u003Cli>What is the overall size of the tool?\u003C\u002Fli>\u003Cli>What specific forming dimensions are involved?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>These details affect machine compatibility and clamping options.\u003C\u002Fp>\u003Ch3>4. Substructures & Frames\u003C\u002Fh3>\u003Cul>\u003Cli>Are substructures available?\u003C\u002Fli>\u003Cli>Will these be provided?\u003C\u002Fli>\u003Cli>Is a suitable frame available?\u003C\u002Fli>\u003Cli>Is a top plug required – and if so, is it included?\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:959\u002F887;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCross_section_of_an_upper_punch_thermoforming_tool_e047f0f55f.webp\" alt=\"Cross section of an upper punch thermoforming tool\" width=\"959\" height=\"887\">\u003C\u002Ffigure>\u003Cp>All of these elements are important to ensure that the tool can be correctly installed on the target machine.\u003C\u002Fp>\u003Ch3>5. Base Plate\u003C\u002Fh3>\u003Cul>\u003Cli>What are the dimensions of the base plate on which thermoforming has previously been carried out?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSegment_carrier_plate_d1b0fdd747.webp\" alt=\"Segment carrier plate\">\u003C\u002Fp>\u003Ch3>6. Cooling\u003C\u002Fh3>\u003Cul>\u003Cli>What type of cooling does the tool have?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This is a relevant factor for cycle times and repeatability (see blog article: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">Thermoforming tools for plastic thermoformed parts\u003C\u002Fa>).\u003C\u002Fp>\u003Ch3>7. Number of Cavities\u003C\u002Fh3>\u003Cul>\u003Cli>How many cavities does the tool have?\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️\u003Cb>Single-Cavity Tooling:\u003C\u002Fb> One part per cycle, ideal for small production volumes and low tooling costs.\n\u003Cbr>\n\u003Cb>Multi-Cavity Tooling: \u003C\u002Fb> Multiple identical parts per cycle, with higher tooling costs but significantly lower unit costs in series production.\u003C\u002Fp>\n \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>8. Previously Used Machine\u003C\u002Fh3>\u003Cul>\u003Cli>On which machine (manufacturer, model) has the tool been used so far?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This information helps facilitate the compatibility assessment. formary operates the following machines in its portfolio:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Froll-production\">\u003Cstrong>Roll-Fed Machines:\u003C\u002Fstrong>\u003C\u002Fa>\u003Cul>\u003Cli>Illig RV\u003C\u002Fli>\u003Cli>Illig IC-RD\u003C\u002Fli>\u003Cli>Illig IC-RDK\u003C\u002Fli>\u003Cli>Illig IC-RDKP\u003C\u002Fli>\u003Cli>Kiefel KMD\u003C\u002Fli>\u003Cli>Kiefel KMV\u003C\u002Fli>\u003Cli>Kiefel KTR\u003C\u002Fli>\u003Cli>Hamer TFP\u003C\u002Fli>\u003Cli>Gabler Focus\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">\u003Cstrong>Sheet-Fed Machines:\u003C\u002Fstrong>\u003C\u002Fa>\u003Cul>\u003Cli>Geiss T10\u003C\u002Fli>\u003Cli>Geiss U8\u003C\u002Fli>\u003Cli>Illig UA\u003C\u002Fli>\u003Cli>Berg M7\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>9. Trimming and Post-Processing Tools\u003C\u002Fh3>\u003Cp>Depending on the downstream processing, the following documents or fixtures are required:\u003C\u002Fp>\u003Ch4>Milled Parts\u003C\u002Fh4>\u003Cul>\u003Cli>Are milling fixtures available?\u003C\u002Fli>\u003Cli>Is the milling program available?\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Punched \u002F Die-Cut Parts\u003C\u002Fh4>\u003Cul>\u003Cli>Are the required punching tools available?\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>10. Material Data Sheet\u003C\u002Fh3>\u003Cul>\u003Cli>Can you provide a material data sheet for the processed material?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This ensures that parts can be manufactured identically after the tool transfer.\u003C\u002Fp>\u003Ch3>11. Sample Parts\u003C\u002Fh3>\u003Cp>Are sample parts available that you can provide to us for evaluation? formary uses these samples for:\u003C\u002Fp>\u003Cul>\u003Cli>Dimensional analyses\u003C\u002Fli>\u003Cli>Surface comparisons\u003C\u002Fli>\u003Cli>Functional testing\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:974\u002F774;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fimage_22_1_f204d88053.webp\" alt=\"Musterteile Tiefziehen\" width=\"974\" height=\"774\">\u003C\u002Ffigure>\u003Ch2>Tool Transfer Checklist\u003C\u002Fh2>\u003Cp>The following checklist summarizes which information is required for a fast and secure tool transfer:\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Category\u003C\u002Fth>\u003Cth>Required Information\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>CAD Data\u003C\u002Ftd>\u003Ctd>3D\u002F2D files, tool geometry\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Images\u003C\u002Ftd>\u003Ctd>Detailed photos, condition, vacuum ports\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Dimensions\u003C\u002Ftd>\u003Ctd>Tool dimensions, base plate\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Additional Elements\u003C\u002Ftd>\u003Ctd>Frame, substructure, top plug\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Machine Information\u003C\u002Ftd>\u003Ctd>Previously used machine type\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cavities\u003C\u002Ftd>\u003Ctd>Number of forming cavities\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Cooling\u003C\u002Ftd>\u003Ctd>Type of tool cooling\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Trimming Tools\u003C\u002Ftd>\u003Ctd>Milling fixture, milling program, or punching tool\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Material\u003C\u002Ftd>\u003Ctd>Data sheet of the material used\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Sample Parts\u003C\u002Ftd>\u003Ctd>Samples for evaluation\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Conclusion: Tool transfer as a fast and economical route to series production\u003C\u002Fh2>\u003Cp>Tool transfer in deep drawing is one of the most efficient ways to continue producing existing components without delay and without incurring new tooling costs. Companies benefit from validated product quality and fast, cost-efficient series production. With formary, you receive a technical review within a very short time and secure integration of your tool into production.\u003C\u002Fp>\u003Cp>Are you currently planning your deep drawing project? Then \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">\u003Cstrong>contact\u003C\u002Fstrong>\u003C\u002Fa> us—we will support you from the initial idea to implementation.\u003C\u002Fp>","tool-transfer-in-thermoforming",{"id":420,"documentId":848,"createdAt":849,"updatedAt":850,"publishedAt":85,"locale":10,"title":851,"introduction":852,"content":853,"slug":854},"vn26k1zejmlc8gq15o6px5gz","2026-01-26T14:15:04.835Z","2026-05-27T13:35:49.639Z","The Biggest Challenges for Manufacturing Companies & Supply Chain Management in 2026","Supply chains have never been as complex and volatile as they are today: geopolitical tensions, capacity bottlenecks, rising raw material prices worldwide, and national energy costs. Companies that want to remain competitive must reassess their supply chain management (SCM).","\u003Ch2>\u003Cspan style=\"color:#005250;\">Current Challenges in Procurement & Supply Chain Management – Key Takeaways\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Increasing time pressure:\u003C\u002Fstrong> Product life cycles continue to shorten, while quotation and development processes in many companies – including smaller ones – take too long.\u003C\u002Fli>\u003Cli>\u003Cstrong>Growing supply chain risks:\u003C\u002Fstrong> Corporations and large SMEs increasingly rely on multi-sourcing and early warning systems to mitigate geopolitical risks and disruptions.\u003C\u002Fli>\u003Cli>\u003Cstrong>Lack of cost transparency:\u003C\u002Fstrong> Prices and manufacturability are opaque; fragmented manufacturing markets make quotation comparisons difficult – often the most efficient supplier is not selected.\u003C\u002Fli>\u003Cli>\u003Cstrong>Rising quality management (QM) risks:\u003C\u002Fstrong> Inspection reports are missing; QM responsibilities and certifications are unclear. Manufacturing topics such as tolerances and surfaces are clarified too late.\u003C\u002Fli>\u003Cli>\u003Cstrong>Unclear project status:\u003C\u002Fstrong> Without digital tracking, order processes remain intransparent. Delays are communicated too late.\u003C\u002Fli>\u003Cli>\u003Cstrong>Lack of technical consulting:\u003C\u002Fstrong> Suppliers too often act purely as contract manufacturers without advising on design, materials, or application.\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Biggest Supply Chain Management Challenges in 2026?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>The new year 2026 will confront procurement in manufacturing companies with profound changes. This applies in particular to the growing supply chain management challenges – ranging from global dependencies to massive planning volatility. The most significant challenges include:\u003C\u002Fp>\u003Col>\u003Cli>Increasing time pressure\u003C\u002Fli>\u003Cli>Unstable supply chains\u003C\u002Fli>\u003Cli>Lack of end-to-end transparency\u003C\u002Fli>\u003Cli>Rising cost pressure\u003C\u002Fli>\u003Cli>High quality and documentation requirements\u003C\u002Fli>\u003Cli>Missing technical consulting\u003C\u002Fli>\u003C\u002Fol>\u003Cp>More details in the sections below.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Time Pressure Due to Shorter Product Life Cycles\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1200\u002F400;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FZeit_ist_geld_1_99b781d148.png\" alt=\"Hand, die eine Uhr hält \" width=\"1200\" height=\"400\">\u003C\u002Ffigure>\u003Cp>Product life cycles are becoming shorter, while many quotation and procurement processes are outdated. Time-consuming manual coordination, a lack of automation, and lengthy internal approval steps delay quotations, lead times, and production releases.\u003C\u002Fp>\u003Cp>To address these challenges, companies are increasingly adopting scenario simulations and automated forecasting processes to better plan tooling and material capacities and optimize procurement processes.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ Especially in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\"> plastic thermoforming, \u003C\u002Fa> where tooling costs, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\"> material selection \u003C\u002Fa>  and first article inspections are critical, delays occur quickly and can push market launches back by weeks.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Supply Chain Risk & Resilience Pressure\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Large companies today expect supply chains not only to cope with disruptions but to actively anticipate them. Key developments include:\u003C\u002Fp>\u003Cul>\u003Cli>Multi-sourcing instead of single sourcing\u003C\u002Fli>\u003Cli>Early warning systems & control towers\u003C\u002Fli>\u003Cli>Collaborative supplier models\u003C\u002Fli>\u003C\u002Ful>\u003Cp>These trends clearly show that companies must actively address supply chain management challenges to secure resilience and competitiveness.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ For plastic thermoformed parts, this means companies can no longer rely on single, historically grown suppliers—regardless of location or region. Global supply chains require regional redundancies to minimize geopolitical, logistical, and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fmaterial-shortage-how-formary-can-help\"> material supply \u003C\u002Fa>  risks. Otherwise, companies face significant risks, especially in series projects with short time-to-market requirements.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Lack of Cost Transparency in the Procurement Market\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In many B2B manufacturing processes, including plastic thermoforming, quotations are rarely directly comparable. Key reasons include:\u003C\u002Fp>\u003Cul>\u003Cli>Machinery and automation levels (cycle times, complexity)\u003C\u002Fli>\u003Cli>Different tooling concepts\u003C\u002Fli>\u003Cli>Variable costing methodologies\u003C\u002Fli>\u003Cli>Material strategies (purchasing prices, stock materials, in-house extrusion)\u003C\u002Fli>\u003Cli>Margin structures depending on current capacity utilization\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This lack of price transparency has become an underestimated supply chain management challenge, as it directly affects planning reliability and procurement efficiency. Traditional negotiations are no longer sufficient: companies require data-driven analysis tools, price benchmarks, and manufacturability assessments to make robust decisions.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Insufficient Quality Assurance Across the Project Lifecycle\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1536\u002F1024;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FQualitaet_und_Sicherheit_im_Thermoforming_gewaehrleisten_6c7b4c4ea4.webp\" alt=\"Fehlende Qualitätssicherung als eine der großen SCM Herausforderungen\" width=\"1536\" height=\"1024\">\u003C\u002Ffigure>\u003Cp>A frequent bottleneck in supply chain management is \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fquality-assurance\">quality management (QM).\u003C\u002Fa> Typical issues include:\u003C\u002Fp>\u003Cul>\u003Cli>Unclear QM responsibilities\u003C\u002Fli>\u003Cli>Missing or incomplete inspection reports\u003C\u002Fli>\u003Cli>Late definition of critical specifications (tolerances, surfaces, material behavior)\u003C\u002Fli>\u003Cli>Lack of early warning systems for deviations\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The combination of quality risks and supply chain complexity significantly amplifies SCM challenges throughout the entire project lifecycle. Without end-to-end QM processes, uncertainty arises in production and first article inspection, leading to rework, delays, and increased risks in series production.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Intransparent Order Processing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Once orders are placed, they often turn into a \u003Cstrong>black box\u003C\u002Fstrong>:\u003C\u002Fp>\u003Cul>\u003Cli>What is the project status?\u003C\u002Fli>\u003Cli>When is the next milestone?\u003C\u002Fli>\u003Cli>Have approvals been granted?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Without structured project communication and digital traceability, status information is quickly lost. The result is misunderstandings, delayed deliveries, and high internal coordination effort.\u003C\u002Fp>\u003Cp>In 2026, transparency in supply chains will be a fundamental requirement: control tower models, tracking tools, and real-time data are becoming essential to make risks visible, increase responsiveness, and resolve critical supply chain management challenges.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">6. Little to No Technical Consulting\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:5184\u002F3456;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FLieferant_werden_formary_288c639794.jpg\" alt=\"Fehlende technische Beratung als Supply Chain Management Herausforderung\" width=\"5184\" height=\"3456\">\u003C\u002Ffigure>\u003Cp>Many manufacturers see themselves merely as executors of CAD data. Active technical consulting often does not take place. Common consequences include:\u003C\u002Fp>\u003Cul>\u003Cli>Technical questions remain unanswered\u003C\u002Fli>\u003Cli>Special requirements are not reviewed\u003C\u002Fli>\u003Cli>Lack of material and design optimization\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Yet consulting on material selection, \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-for-manufacturing-guide\">design for manufacturability,\u003C\u002Fa> and application engineering would be a key lever in addressing current procurement challenges and achieving economically and functionally optimal products.\u003C\u002Fp>\u003Ch4>Overview: Key Challenges in Procurement and Supply Chain Management 2026\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Challenge\u003C\u002Fth>\u003Cth>Classification\u003C\u002Fth>\u003Cth>Impact on Companies\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Time pressure & shorter product life cycles\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Outdated procurement processes, long quotation and approval cycles slow down projects.\u003C\u002Ftd>\u003Ctd>Delayed market entry & rising internal costs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Supply chain & resilience pressure\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Geopolitical risks, material shortages, and the need for multi-sourcing and early warning systems.\u003C\u002Ftd>\u003Ctd>Greater dependency & risk of unstable supply chains\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Lack of cost transparency\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Prices, material costs, and manufacturability are difficult to compare; fragmented market.\u003C\u002Ftd>\u003Ctd>Unreliable cost calculations & more difficult purchasing decisions\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Quality and QA risks\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Missing inspection reports, late definition of specifications, and inconsistent quality management.\u003C\u002Ftd>\u003Ctd>Higher scrap rates, rework & scheduling risks\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Project & process intransparency\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Order status often remains unclear due to missing digital tracking.\u003C\u002Ftd>\u003Ctd>Increased communication effort; unreliable delivery schedules\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Lack of technical consulting\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Suppliers often act solely as executors without material or design input.\u003C\u002Ftd>\u003Ctd>Unoptimized components, higher costs & technical risks\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Companies Are Most Affected by Current Supply Chain Risks and Procurement Challenges?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Manufacturing companies particularly affected include those with:\u003C\u002Fp>\u003Cul>\u003Cli>High product variant diversity\u003C\u002Fli>\u003Cli>Short product life cycles\u003C\u002Fli>\u003Cli>International supply chains\u003C\u002Fli>\u003Cli>High quality and documentation requirements\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This includes sectors such as \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmechanical-engineering\">mechanical engineering,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">medical technology,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">electronics,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">automotive,\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Findustrial-solutions\">industrial manufacturing.\u003C\u002Fa>\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">How formary Systematically Solves These Challenges in the Procurement of Plastic Thermoformed Parts\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FEnglish_formary_Website_Mockup_0829d25eeb.webp\" alt=\"English formary Website Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>These procurement challenges are particularly evident in plastic thermoformed parts: missing data, a fragmented supplier market, and major price differences complicate fast and secure decision-making. Rather than applying isolated solutions, formary digitizes and structures the entire procurement process for plastic thermoformed parts.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Accelerated Processes and Reduced Time-to-Market\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>As a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fb2b-platforms-in-plastics-processing\">B2B platform,\u003C\u002Fa> formary fully digitizes inquiry, quotation, and project execution:\u003C\u002Fp>\u003Cul>\u003Cli>Structured inquiry \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa> with CAD upload\u003C\u002Fli>\u003Cli>Complete requests without manual follow-ups\u003C\u002Fli>\u003Cli>Quotations within 24 hours\u003C\u002Fli>\u003Cli>Integrated \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">design-for-manufacturing analysis\u003C\u002Fa>\u003C\u002Fli>\u003C\u002Ful>\u003Cp>As a result, project timelines are significantly shortened. Time-to-prototype is reduced from \u003Cstrong>6–8 weeks to 2–3 weeks\u003C\u002Fstrong>, and overall project duration decreases by \u003Cstrong>up to 70%\u003C\u002Fstrong>.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ \u003Cb>Practical example:\u003C\u002Fb> The collaboration with \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcase-studies\u002Fi-thera-medical-1\"> iThera Medical \u003C\u002Fa>  demonstrates how effective this acceleration can be. For a new generation of devices, the MedTech company required \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\"> medical enclosures \u003C\u002Fa> with demanding technical requirements and extremely short lead times.\n\u003Cbr>\n\u003Cbr>\nformary optimized the design for cost efficiency, flexibly distributed manufacturing across its network, and organized alternative material sources when a supplier failed. The result: on-time, high-precision prototypes despite material shortages – and around 50% cost reduction in the project.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transparent Costs and Reliable Comparability\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>formary creates cost transparency through:\u003C\u002Fp>\u003Cul>\u003Cli>AI-powered supplier matching\u003C\u002Fli>\u003Cli>Direct manufacturer pricing without hidden markups\u003C\u002Fli>\u003Cli>Uniformly structured quotations in the customer portal\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Procurement teams gain reliable decision-making data and reduce project costs by \u003Cstrong>up to 30%\u003C\u002Fstrong>.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ Learn more in our article: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002F5-levers-formary-uses-to-reduce-thermoforming-costs\"> 5 Levers formary Uses to Reduce Thermoforming Costs.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">End-to-End Quality Assurance from the Start\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Quality assurance is an integral part of the formary process:\u003C\u002Fp>\u003Cul>\u003Cli>Exclusively audited, ISO-certified partner network\u003C\u002Fli>\u003Cli>Digital DfM analysis with simulation of critical geometries\u003C\u002Fli>\u003Cli>Complete QA and inspection report documentation\u003C\u002Fli>\u003Cli>Clear responsibilities throughout the entire project lifecycle\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Errors are detected early—before they become costly in tooling or series production.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:131\u002F150;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FToleranzen_Icon_d0b3f87455.svg\" alt=\"Durchgängige Qualitätssicherung\" width=\"131\" height=\"150\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transparent and Controllable Order Processing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Through the formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Faccount\u002Flogin\">customer portal,\u003C\u002Fa> companies retain full visibility at all times:\u003C\u002Fp>\u003Cul>\u003Cli>Real-time project status\u003C\u002Fli>\u003Cli>Digital approvals of CAD data and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fprototyping\">prototypes\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Delivery and shipment tracking\u003C\u002Fli>\u003Cli>Centralized storage of all project documentation\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This makes order processing predictable and traceable.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Technical Consulting Instead of Pure Contract Manufacturing\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>formary acts as a \u003Cstrong>single point of contact\u003C\u002Fstrong> and assumes technical responsibility:\u003C\u002Fp>\u003Cul>\u003Cli>Consulting on materials, design, and feasibility\u003C\u002Fli>\u003Cli>Combination of digital tools (such as the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D tray generator\u003C\u002Fa>), DfM analysis, and manufacturing expertise\u003C\u002Fli>\u003Cli>Support from prototype to series production (see: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">Project Planning in Thermoforming\u003C\u002Fa>)\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Benefits of formary in the Procurement Process\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>formary Benefit\u003C\u002Fth>\u003Cth>What formary Provides\u003C\u002Fth>\u003Cth>Concrete Value for Companies\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Accelerated project timelines\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Inquiry, quotation, and execution are fully digitized: quotations within 24 hours, time-to-prototype reduced from 6–8 to 2–3 weeks.\u003C\u002Ftd>\u003Ctd>Faster market entry, shorter development cycles, reduced coordination effort\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Transparent costs & comparability\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>AI-driven supplier matching and direct manufacturer pricing create clarity without markups.\u003C\u002Ftd>\u003Ctd>Up to 30% cost savings and a reliable decision-making basis\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>End-to-end quality assurance\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>ISO-certified partners, DfM analyses, and complete inspection reports integrated into the process.\u003C\u002Ftd>\u003Ctd>Early error detection and fewer production and series risks\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Digital order & project transparency\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Real-time status, digital approvals, shipment tracking, and a document portal.\u003C\u002Ftd>\u003Ctd>Predictable supply chains, less coordination effort, higher process reliability\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Technical consulting & know-how\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>formary delivers design, material, and feasibility consulting instead of pure manufacturing.\u003C\u002Ftd>\u003Ctd>Optimized components, fewer revision loops, lower risk of misinvestment\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Cstrong>Flexible manufacturing network\u003C\u002Fstrong>\u003C\u002Ftd>\u003Ctd>Distributed manufacturing and alternative sources prevent bottlenecks in case of supplier failures.\u003C\u002Ftd>\u003Ctd>Higher resilience and reduced supply chain risk\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Conclusion – SCM & Plastic Parts Procurement Must Be Rethought in 2026\u003C\u002Fh2>\u003Cp>Procurement processes in 2026 are characterized by increasing time pressure, lack of transparency, and insufficient quality assurance. At the same time, digital project transparency and technical consulting are often missing.\u003C\u002Fp>\u003Cp>formary demonstrates how digital, technically sound, and transparent procurement of plastic thermoformed parts can look today—faster, more reliable, and more economical.\u003C\u002Fp>\u003Cp>Send us your inquiry or contact us directly with any questions!\u003C\u002Fp>","supply-chain-management-challenges-2026",{"id":856,"documentId":857,"createdAt":858,"updatedAt":859,"publishedAt":85,"locale":10,"title":860,"introduction":861,"content":862,"slug":863},593,"d0bpe5i3n33glzx3nygakmmk","2026-03-23T11:12:23.249Z","2026-05-27T13:39:38.862Z","Unit Costs and Tooling Costs in Thermoforming: Cost Factors and Scalability","The costs in plastic thermoforming are a crucial factor for the economic efficiency and planning of a project. They depend on various influences along the process chain and change depending on production volume and requirements. This article explains how costs in plastic thermoforming are composed, how they develop with increasing quantities and when the process becomes particularly worthwhile.","\u003Ch2>Relationship Between Unit Costs and Tooling Costs in Thermoforming – Key Facts at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>The costs of thermoforming mainly consist of tooling, material, manufacturing, energy and labor costs\u003C\u002Fli>\u003Cli>Tooling costs are incurred once and typically range between €800 and €10,000\u003C\u002Fli>\u003Cli>Unit costs usually range between €0.20 and €15 per part depending on material, geometry and production volume. For particularly large or complex parts costs may be higher\u003C\u002Fli>\u003Cli>As production volume increases unit costs decrease significantly especially when moving from very small batches to small series\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request thermoformed part now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What Factors Determine Thermoforming Costs?\u003C\u002Fh2>\u003Cp>Several cost factors interact in the production of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoformed plastic parts\u003C\u002Fa>. These determine both the total cost of a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">thermoforming project\u003C\u002Fa> and how unit costs evolve with increasing production volume.\u003C\u002Fp>\u003Cfigure class=\"table\" style=\"width:80.5%;\">\u003Ctable class=\"ck-table-resized\">\u003Ccolgroup>\u003Ccol style=\"width:29.11%;\">\u003Ccol style=\"width:70.89%;\">\u003C\u002Fcolgroup>\u003Cthead>\u003Ctr>\u003Cth>Cost Factors in Thermoforming\u003C\u002Fth>\u003Cth>Composition of these factors\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Tooling Costs\u003C\u002Ftd>\u003Ctd>Concept, design and engineering of tooling data as well as milling and manufacturing of the thermoforming tool\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Material Costs\u003C\u002Ftd>\u003Ctd>Purchase price of plastic semi finished products such as sheets or films from manufacturers or suppliers\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Manufacturing Costs\u003C\u002Ftd>\u003Ctd>Machine hourly rate multiplied by the total production time\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Energy Costs\u003C\u002Ftd>\u003Ctd>Electricity costs for the machine as well as energy for automated processes and peripheral equipment\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Labor Costs\u003C\u002Ftd>\u003Ctd>Personnel costs for machine operation and manual processing steps\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>Tooling Costs as Initial Investment\u003C\u002Fh2>\u003Cp>Tooling costs in thermoforming are a one time initial investment. They occur at the beginning of a project and do not recur afterward. Typical thermoforming tools cost between approximately €800 and €10,000 depending on size, complexity and number of cavities. Higher costs usually result from more complex tool designs.\u003C\u002Fp>\u003Cp>Material, geometry and the machine for which the tool is designed also have a major influence. Additional components such as stacking systems or substructures can further increase the price. With increasing production volume these fixed costs are distributed over more parts which significantly reduces the tooling cost share per unit.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1280\u002F720;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehwerkzeug_aus_Aluminium_1_093e9a4690.webp\" alt=\"Tiefziehwerkzeug aus Aluminium\" width=\"1280\" height=\"720\">\u003Cfigcaption>\u003Cspan style=\"background-color:hsl(0,0%,100%);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">Aluminum production tool\u003C\u002Fspan>\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>What Does a Thermoformed Part Cost per Unit?\u003C\u002Fh2>\u003Cp>Unit costs in thermoforming depend on several factors:\u003C\u002Fp>\u003Cul>\u003Cli>Material used\u003C\u002Fli>\u003Cli>Initial material thickness\u003C\u002Fli>\u003Cli>Part size and geometry\u003C\u002Fli>\u003Cli>Degree of automation in production\u003C\u002Fli>\u003Cli>Production quantity\u003C\u002Fli>\u003Cli>etc\u003C\u002Fli>\u003C\u002Ful>\u003Cp>For standard trays, inlays and containers unit costs typically range between €0.20 and €15 per piece. For large housings or heavily post processed parts costs can be significantly higher. The exact price depends on the specific project and part requirements\u003C\u002Fp>\u003Ch2>How Costs Develop with Increasing Production Volume\u003C\u002Fh2>\u003Cp>As production volume increases unit costs in thermoforming decrease. Machine downtime is spread over more parts and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fautomation-of-production-with-trays\">automated processes \u003C\u002Fa>enable higher output per hour.\u003C\u002Fp>\u003Cp>At the same time the cost structure changes. In smaller series tooling costs make up a large share. In larger series material costs become the dominant factor.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:850\u002F352;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGraphic_Development_Cost_factor_by_Units_8880ace877.webp\" alt=\"Graphic Development Cost factor by number of Units\" width=\"850\" height=\"352\">\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 Example: At around 1,000 units tooling costs may account for about 60 percent of total costs\nAt 10,000 units their share often drops to around 10 percent while the share of material costs increases accordingly. \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch2>Unit Cost Reduction Between Small and Medium Series\u003C\u002Fh2>\u003Cp>The greatest reduction in unit costs typically occurs when moving from very small quantities to small series. Even the step from a micro series of less than 10 parts to a small series of less than 100 parts can bring significant cost advantages.\u003C\u002Fp>\u003Cp>Another economic leap often occurs when transitioning to medium series with up to approximately 5,000 parts as materials can often be sourced more cost effectively. In large series unit costs usually decrease only slightly and only minor optimizations remain.\u003C\u002Fp>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">For more information, see \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fguide-to-cost-reduction-in-thermoforming\">\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">Cost Reduction in Thermoforming\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">.\u003C\u002Fspan>\u003C\u002Fp>\u003Ch2>Cost Advantages of Thermoforming Compared to Other Processes\u003C\u002Fh2>\u003Cp>Thermoforming offers clear economic advantages:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cp>Lower tooling costs since tools are significantly cheaper than injection molding tools.\u003C\u002Fp>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">(Read more in our article \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Finjection-molding-vs-thermoforming\">\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">Injection Molding vs. Thermoforming\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">)\u003C\u002Fspan>\u003C\u002Fp>\u003C\u002Fli>\u003Cli>Less post processing since colored \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsheet-production\">plastic sheets\u003C\u002Fa> often eliminate the need for \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpainting-plastic\">painting\u003C\u002Fa>.\u003C\u002Fli>\u003Cli>Large parts from a single tool since sheets up to approximately 4,000 × 3,000 mm enable large thin walled parts.\u003C\u002Fli>\u003Cli>Economical even for small series since low tooling costs allow a cost efficient project start.\u003C\u002Fli>\u003Cli>Fast and cost effective prototyping since tools made from Ureol or 3D printing enable quick prototypes and sample parts.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 If you'd like to compare thermoforming with other plastic processing methods, you'll find a clear comparison of the most common methods in our article \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-manufacturing-processes-compared\">\"Plastic manufacturing processes compared\".\u003C\u002Fa> \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch2>High Scalability in Series Production\u003C\u002Fh2>\u003Cp>An often underestimated advantage of thermoforming is its long term scalability. Once the tool is available production can be scaled almost indefinitely. The initial tooling investment becomes less significant with each additional unit produced.\u003C\u002Fp>\u003Cp>As a result costs per part continuously decrease with increasing production volume which makes the process especially attractive for projects that grow after market entry.\u003C\u002Fp>\u003Chr>\u003Ch2>Conclusion\u003C\u002Fh2>\u003Cp>Thermoforming is an economically attractive process especially for projects that start with smaller series and later scale. Tooling costs are a one time and manageable investment and unit costs decrease significantly as production volume increases\u003C\u002Fp>\u003Cp>Anyone who considers costs early and plans for volume growth can use thermoforming strategically and fully leverage its economic advantages. If you have further questions feel free to contact us. We are happy to help.\u003C\u002Fp>","unit-and-tooling-costs-in-thermoforming",{"id":865,"documentId":866,"createdAt":867,"updatedAt":868,"publishedAt":85,"locale":10,"title":869,"introduction":870,"content":871,"slug":872},652,"nrq09p854jbyy4i5docnyhy8","2026-04-16T15:19:18.196Z","2026-05-27T13:47:36.993Z","Guide: Top 5 Tips for Cost Reduction in Thermoforming","Costs in plastic thermoforming are primarily determined by design, material selection, and tooling design. Many cost drivers are not immediately apparent and often only become visible late in the development process. This is precisely where unnecessary costs frequently arise, costs that can be avoided with the right measures.","\u003Ch2>Reducing Costs in Thermoforming - Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>Part design, material selection and mold design are the most effective ways to reduce costs\u003C\u002Fli>\u003Cli>Production-optimized design sustainably lowers unit costs\u003C\u002Fli>\u003Cli>Reduced material usage directly minimizes costs\u003C\u002Fli>\u003Cli>Efficient molds improve cost-effectiveness\u003C\u002Fli>\u003Cli>Early consideration during the development phase is crucial\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>What causes high costs in thermoforming?\u003C\u002Fh2>\u003Cp>For many companies, the biggest cost drivers in thermoforming are not immediately apparent. Especially without experience in design and tooling, they often only become visible \u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">once adjustments are already requiring significant effort and incurring additional costs.\u003C\u002Fspan>\u003C\u002Fp>\u003Cp>In addition to material usage, tool complexity and the associated process steps play a particularly important role. It is often underestimated that even small adjustments in the design can have a major impact. This is precisely where the greatest potential lies for reducing costs in thermoforming. We support you in designing your components to be cost-optimized from the very beginning.\u003C\u002Fp>\u003Ch2>5 Tips for Reducing Costs in Thermoforming\u003C\u002Fh2>\u003Cp>These tips can be considered right from the start of your \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">project \u003C\u002Fa>to keep the total cost of your plastic thermoformed parts as economical as possible.\u003C\u002Fp>\u003Cp>With \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tools\u003C\u002Fa>, you have the following options:\u003C\u002Fp>\u003Cul>\u003Cli>Produce multiple parts with a single tool\u003C\u002Fli>\u003Cli>Avoid moving parts\u003C\u002Fli>\u003Cli>Use multi-cavity tools\u003C\u002Fli>\u003C\u002Ful>\u003Cp>The choice of material also determines the costs involved in thermoforming. Therefore, you should:\u003C\u002Fp>\u003Cul>\u003Cli>Select materials consciously and according to your needs\u003C\u002Fli>\u003Cli>Use pre-colored semi-finished products\u003C\u002Fli>\u003Cli>Reduce material usage through intelligent design\u003C\u002Fli>\u003C\u002Ful>\u003Cp>In the following sections, we explain these steps in detail.\u003C\u002Fp>\u003Ch3>1. Produce multiple parts with a single mold\u003C\u002Fh3>\u003Cp>An effective way to reduce unit costs is the efficient use of the mold. The goal is to achieve the highest possible output per cycle. Multi-cavity molds are standard practice in thermoforming and allow for the simultaneous production of multiple identical components. However, combining different components in a single mold also offers significant savings potential. See how we use multi-cavity molds in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcase-studies\u002Fproject-with-naext\">case study with NAEXT.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1140\u002F814;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGrafik_Mehrfach_Nutzen_Werkzeug_84be103d5a.webp\" alt=\"Grafik Mehrfach-Nutzen-Werkzeug\" width=\"1140\" height=\"814\">\u003Cfigcaption>Graphical depiction of a multi-purpose tool\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>2. Avoid Moving Parts in the Tool\u003C\u002Fh3>\u003Cp>Complex part geometries, particularly undercuts, require the use of moving elements in the tool. These significantly increase thermoforming costs and maintenance requirements.\u003C\u002Fp>\u003Cp>Therefore, you should check during the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fdesign-guidelines-for-thermoformed-parts\">design\u003C\u002Fa> phase whether the workpiece can be adapted to eliminate this complexity.\u003C\u002Fp>\u003Cp>\u003Cstrong>Typical optimizations include:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Eliminating undercuts\u003C\u002Fli>\u003Cli>Adjusting draft angles\u003C\u002Fli>\u003Cli>Simplifying the geometry\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:745\u002F849;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGrafik_Hinterschnitt_681155f614.webp\" alt=\"Grafik Hinterschnitt\" width=\"745\" height=\"849\">\u003Cfigcaption>Depiction of a undercut\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 Undercuts are made possible by retractable elements in the mold. The mold is equipped with sliders that “fold away” during demolding (flap mold). This makes the demolding process more complex and the mold more expensive. Therefore, they should always be kept to a minimum.\n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch3>3. Choose the material carefully and based on your specific needs\u003C\u002Fh3>\u003Cp> \u003C\u002Fp>\u003Cp>A common mistake in practice is selecting a \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fkunststoff-lackieren-das-ist-bei-der-lackierung-von-thermoplasten-zu-beachten\">material\u003C\u002Fa> that offers more capabilities than are actually necessary. This so-called “oversizing” unnecessarily leads to higher costs in thermoforming. Instead, material selection should consistently follow the bottom-up principle: Choose exactly the material that precisely meets the requirements.\u003C\u002Fp>\u003Cp>This ensures a more economical solution with the same functionality.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 To learn how to choose the right material for your project, check out our white paper \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-2\"> In 6 Steps to the Right Plastic for Your Thermoforming Project. \u003C\u002Fa>  \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch3>4. Use pre-colored semi-finished products for colored parts\u003C\u002Fh3>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2000\u002F1498;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefgezogene_Kunststoffwanne_rot_nachlackiert_77d2c1c31f.webp\" alt=\"Tiefgezogene Kunststoffwanne rot nachlackiert\" width=\"2000\" height=\"1498\">\u003Cfigcaption>Post-painted plastic tray\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>In many projects, coloring is performed later in the process, such as through \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fpainting-plastic\">plastic painting.\u003C\u002Fa> This adds an extra step that costs time and money.\u003C\u002Fp>\u003Cp>If pre-colored semi-finished products are used instead, this step can be eliminated. However, this requires that the quantities and the supply chain allow for such procurement.\u003C\u002Fp>\u003Ch3>5. Reduce Material Usage Through Intelligent Design\u003C\u002Fh3>\u003Cp>Material is one of the biggest cost factors in thermoforming. That’s why it’s particularly worthwhile to focus on this area. Through clever design, material thickness can be reduced without compromising stability. Reinforcing structures such as ribs are often used for this purpose.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:727\u002F874;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTransverse_Ribs_7d0dcdbb54.webp\" alt=\"Transverse Ribs\" width=\"727\" height=\"874\">\u003C\u002Ffigure>\u003Cp>\u003Cstrong>Typical benefits include:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Lower material consumption\u003C\u002Fli>\u003Cli>Lower unit costs\u003C\u002Fli>\u003Cli>Consistent component quality\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 When adding ribs or struts, keep the following in mind: Too many closely spaced transverse ribs negatively affect the aspect ratio and the distance between individual transverse ribs must be at least as great as their depth.\n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Chr>\u003Ch2>Conclusion: Reducing costs in thermoforming starts with the right design\u003C\u002Fh2>\u003Cp>The greatest potential for cost savings in thermoforming doesn’t arise during production, but rather during the development and design phase. By focusing early on material-efficient design, simple geometries, and tool-friendly construction, you lay the foundation for consistently low unit costs.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> With our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">DfM analysis\u003C\u002Fa> software, we check your data for \u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(41,41,41);font-family:Roboto, sans-serif;\">thermoformability\u003C\u002Fspan> and determine the best cost-benefit ratio for you.\u003C\u002Fp>","guide-to-cost-reduction-in-thermoforming",{"id":874,"documentId":875,"createdAt":876,"updatedAt":877,"publishedAt":85,"locale":10,"title":878,"introduction":879,"content":880,"slug":881},687,"jdpmz65opqr83h3z61xp3mbl","2026-05-15T13:37:21.153Z","2026-06-02T18:04:57.198Z","What Are Plastic Additives? Functions & Properties Explained","Plastics alone rarely meet all the requirements of industrial applications. It is only through the use of specific additives that materials become robust, flexible, or durable. This is exactly where additives come into play. They specifically alter the properties of plastics, making them suitable for specific applications in the first place. ","\u003Ch2 style=\"margin-left:0px;\">Plastic Additives - Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cp style=\"margin-left:0px;\">Plastic additives are substances added to plastics to specifically improve their properties\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Additives influence the mechanical, thermal, and optical properties of plastics\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Typical examples of plastic additives include lubricants, stabilizers, and flame retardants\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Without additives, many everyday and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Findustrial-solutions\">industrial applications\u003C\u002Fa> would not be possible\u003C\u002Fp>\u003C\u002Fli>\u003C\u002Ful>\u003Cp style=\"margin-left:0px;\">\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request a project with plastic additives now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2 style=\"margin-left:0px;\">What are additives in plastics?\u003C\u002Fh2>\u003Cp style=\"margin-left:0px;\">Additives are chemical substances added to \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> in small quantities to specifically alter their properties. They enable materials to be tailored to specific requirements such as flexibility, durability, or surface behavior.\u003C\u002Fp>\u003Ch3 style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Why are simple plastics sometimes not enough?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Plastics can already meet many requirements, but additives are used when one wants to further improve the properties and adapt them to the intended use. They are typically added during manufacturing as part of the compounding process. This ensures uniform distribution within the material and reliably achieves the desired effect.\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffflakes_in_Haenden_873bd6b3b2.webp\" alt=\"Kunststoffgranulat in den Händen\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch2 style=\"margin-left:0px;\">What types of plastic additives are there?\u003C\u002Fh2>\u003Cp style=\"margin-left:0px;\">There is a wide variety of plastic additives, each of which serves a different function and specifically influences certain material properties.\u003C\u002Fp>\u003Ch3 style=\"margin-left:0px;\">Lubricants\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">Lubricants reduce friction between plastic surfaces. This improves processing and reduces wear on components.\u003C\u002Fp>\u003Ch3 style=\"margin-left:0px;\">Anti-blocking agents\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">Anti-blocking agents prevent plastic surfaces from sticking together. They are primarily used in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">plastic films\u003C\u002Fa> to make them easier to process and stack.\u003C\u002Fp>\u003Ch3 style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Antistatic agents\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Antistatic agents reduce electrostatic charge by increasing the surface conductivity. This prevents dust or dirt from being attracted. For electrical dissipation, conductive additives such as carbon black, carbon fibers, or stainless steel fibers are used, which are particularly relevant where \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fesd-trays\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">ESD protection\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"background-color:hsl(0,0%,100%);\"> is required.\u003C\u002Fspan>\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_esd_schutz_a9091d2887.webp\" alt=\"Abdeckung ESD Schutz\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Ch3 style=\"margin-left:0px;\">Flexibilizers and Plasticizers\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">These additives increase the flexibility and toughness of plastics. They make the material softer and improve its mechanical properties.\u003C\u002Fp>\u003Ch3 style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Flame retardants\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp style=\"margin-left:0px;\">\u003Cspan style=\"background-color:hsl(0,0%,100%);\">Flame retardants reduce the flammability of plastics. They enhance the safety of components exposed to high temperatures or fire. Mineral fillers such as talc are used for this purpose.\u003C\u002Fspan>\u003C\u002Fp>\u003Ch3>Additives for laser marking\u003C\u002Fh3>\u003Cp>These additives improve the quality and legibility of laser markings. They ensure better contrast and more precise marking.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:312\u002F312;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_gravuren_3733c0e8fe.svg\" alt=\"Elektronikgehäuse aus Kunststoff_Individualisierungsmöglichkeiten\" width=\"312\" height=\"312\">\u003C\u002Ffigure>\u003Ch3>Release agents\u003C\u002Fh3>\u003Cp>Release agents reduce adhesion between the plastic and the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">thermoforming tool\u003C\u002Fa>. This facilitates demolding and makes production more efficient.\u003C\u002Fp>\u003Ch3>Colorants\u003C\u002Fh3>\u003Cp>Colorants give plastics a desired color or alter their \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\">optical properties\u003C\u002Fa>. These include pigments and dyes.\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1920;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F0097_bit_002_formary_prod_gall_wanne_890d54e8b0.jpg\" alt=\"Roter Tiefziehbehälter aus Kunststoff mit schmaler Passform\" width=\"1920\" height=\"1920\">\u003C\u002Ffigure>\u003Ch3>Stabilizers\u003C\u002Fh3>\u003Cp>Stabilizers protect plastics from external factors such as UV radiation, heat, or chemical stress and extend the service life of components. To increase mechanical stability and stiffness, glass fibers can also be added; these reinforce the material but also affect its shrinkage behavior during cooling.\u003C\u002Fp>\u003Ch3>Antibacterial Agents and Fungicides\u003C\u002Fh3>\u003Cp>These additives inhibit the growth of bacteria and fungi on the surface. They are primarily used in sensitive areas such as medicine or food packaging\u003C\u002Fp>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_hygieneanforderungen_01_d4c24e6c63.png\" alt=\"Abdeckung mit Hygieneanforderungen\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Ch2>Welche Kunststoffe eignen sich für den Einsatz von Additiven?\u003C\u002Fh2>\u003Cp>ABS and ASA are commonly used for robust and weather-resistant applications because they can be effectively adapted with stabilizers and impact modifiers. HD-PE and PP are suitable for cost-efficient and chemically resistant solutions and are often optimized with lubricants or antistatic agents.\u003C\u002Fp>\u003Cp>PC and PMMA are used when high strength and transparency are required, while PET-A and PET-G are particularly suitable for packaging. PS and PVC are versatile and can be flexibly adapted to technical requirements through additives. The decisive factor is the desired property of the component.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 You can see what distinguishes the different thermoplastics and which applications they are used for in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\">material guide.\u003C\u002Fa>\u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>Overview of Typical Application Areas for Plastic Additives\u003C\u002Fh2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Kunststoff\u003C\u002Fth>\u003Cth>Typische Eigenschaften\u003C\u002Fth>\u003Cth>Häufige Additive\u003C\u002Fth>\u003Cth>Typische Anwendungen\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fasa-plastic\">ASA\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Robust, impact-resistant, weather-resistant\u003C\u002Ftd>\u003Ctd>Stabilizers, impact modifiers\u003C\u002Ftd>\u003Ctd>Housings, trim parts, outdoor applications\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fhd-pe-plastic\">HD-PE\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Cost-efficient, chemically resistant\u003C\u002Ftd>\u003Ctd>Lubricants, antistatic agents\u003C\u002Ftd>\u003Ctd>Packaging, technical components, containers\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpmma-plastic\">PMMA\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>High strength, high transparency\u003C\u002Ftd>\u003Ctd>UV stabilizers, optical additives\u003C\u002Ftd>\u003Ctd>Visible parts, covers, displays\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PET-A\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-g-plastic\">PET-G\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Good processability, food-safe\u003C\u002Ftd>\u003Ctd>Antiblocking agents, stabilizers\u003C\u002Ftd>\u003Ctd>Packaging, blisters, protective packaging\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpvc-plastic\">PVC\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Versatile\u003C\u002Ftd>\u003Ctd>Flame retardants, plasticizers, stabilizers\u003C\u002Ftd>\u003Ctd>Technical components, housings, construction applications\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>Application Examples from Various Industries\u003C\u002Fh2>\u003Cp>Plastic additives are relevant in nearly every industry:\u003C\u002Fp>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">Automotive Industry\u003C\u002Fa>\u003C\u002Fh3>\u003Cul>\u003Cli>Interior trim parts with flame retardants\u003C\u002Fli>\u003Cli>Exterior trim and bumpers with UV stabilizers\u003C\u002Fli>\u003Cli>Housing parts for electronics with antistatic properties\u003C\u002Fli>\u003Cli>Visible interior components with colorants\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">Medical Technology\u003C\u002Fa>\u003C\u002Fh3>\u003Cul>\u003Cli>Antibacterial \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-covers\">housings for medical devices\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Flexible tubing and bags with plasticizers\u003C\u002Fli>\u003Cli>Sterile packaging with stabilizers for shelf life\u003C\u002Fli>\u003Cli>Control elements with antistatic properties\u003C\u002Fli>\u003Cli>Components with high material resistance to cleaning agents\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 For use in medical technology, surface finishes can also be applied to meet functional and hygienic requirements. The advantages: improved cleanability, reduced microbial contamination, and the possibility of properties such as EMC protection, flame retardancy, and UV resistance. More information can be found under \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fsurface-finishing-for-medical-housings\">surface optimization in medical technology.\u003C\u002Fa> \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>Packaging Industry\u003C\u002Fh3>\u003Cul>\u003Cli>Plastic films with anti-blocking agents for improved stackability\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fplastic-food-packaging\">Food packaging\u003C\u002Fa> with antibacterial additives\u003C\u002Fli>\u003Cli>Blister packaging with lubricants for smooth processing\u003C\u002Fli>\u003Cli>Packaging with UV protection for light-sensitive products\u003C\u002Fli>\u003Cli>Colored packaging solutions for brand visibility\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">Electronics\u003C\u002Fa>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Felectronic-enclosures\">Housings for electronic devices\u003C\u002Fa> with flame retardants\u003C\u002Fli>\u003Cli>Connectors with antistatic additives\u003C\u002Fli>\u003Cli>Components with high heat resistance due to stabilizers\u003C\u002Fli>\u003Cli>Covers with defined optical properties\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:640\u002F640;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FESD_Verpackung_mit_Deckel_3aca6be86c.webp\" alt=\"ESD-Verpackung mit Deckel\" width=\"640\" height=\"640\">\u003C\u002Ffigure>\u003Ch3 style=\"margin-left:0px;\">Mechanical Engineering\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Cp style=\"margin-left:0px;\">Covers and protective housings with UV and temperature stabilizers\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Molded parts with release agents for efficient mass production\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Technical components with enhanced mechanical stability\u003C\u002Fp>\u003C\u002Fli>\u003Cli>\u003Cp style=\"margin-left:0px;\">Functional surfaces with optimized tactile and visual properties\u003C\u002Fp>\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Are you unsure which plastic is suitable for your project? You can find out how to identify the right material for your application in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-2\">material guide.\u003C\u002Fa> \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>What are the benefits of plastic additives?\u003C\u002Fh2>\u003Cul>\u003Cli>Targeted improvement of mechanical, thermal, and optical properties\u003C\u002Fli>\u003Cli>Longer service life of components thanks to protection against UV radiation, heat, and chemicals\u003C\u002Fli>\u003Cli>Improved processability and more stable production processes\u003C\u002Fli>\u003Cli>Reduced friction and lower wear\u003C\u002Fli>\u003Cli>Increased safety through flame retardancy and antistatic properties\u003C\u002Fli>\u003Cli>Optimized surfaces for function and appearance\u003C\u002Fli>\u003Cli>Adaptation to specific applications and industry requirements\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>Improved Performance Through Plastic Additives - A Summary\u003C\u002Fh2>\u003Cp>Additives are a key component of plastic solutions and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fproject-planning-in-thermoforming\">thermoforming projects\u003C\u002Fa>. They determine how effective a material is and whether it meets the requirements of a given application.\u003C\u002Fp>\u003Cp>If you use or develop plastic thermoformed parts, you should consider selecting the right additives early on. This will help you avoid problems later on and ensure the quality of your components. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fcontact\">Contact\u003C\u002Fa> us, we’d be happy to advise you!\u003C\u002Fp>","what-are-plastic-additives",{"id":883,"documentId":884,"createdAt":885,"updatedAt":886,"publishedAt":85,"locale":10,"title":887,"introduction":888,"content":889,"slug":890},689,"xqtobwa7ua7cjquhxj3g3b7l","2026-05-19T10:31:21.979Z","2026-06-03T09:21:46.405Z","Plastic Compounds Explained Simply: How Additives Turn Standard Plastics into True High-Performance Materials","In practice, plastics are rarely “pure.” Their properties are specifically tailored to meet specific requirements. This is exactly where plastic compounds come into play. When you develop or procure plastic parts, compounds significantly influence function, cost, and quality. They determine whether a component is robust, UV-resistant, or electrically conductive. Read more in this article.","\u003Ch2>Plastic Compounds - Key Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>Plastic compounds are \u003Cstrong>modified plastics\u003C\u002Fstrong> containing additives or fillers\u003C\u002Fli>\u003Cli>They specifically enhance \u003Cstrong>properties\u003C\u002Fstrong> such as strength, UV resistance, or conductivity\u003C\u002Fli>\u003Cli>Compounds enable \u003Cstrong>customized solutions\u003C\u002Fstrong> for various industries\u003C\u002Fli>\u003Cli>They \u003Cstrong>enhance performance\u003C\u002Fstrong>, but can also increase costs and complexity\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Request a thermoformed part made from plastic compounds now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>What are plastic compounds?\u003C\u002Fh2>\u003Cp>Plastic compounds are \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">plastics\u003C\u002Fa> whose properties are specifically adjusted through the use of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fwhat-are-plastic-additives\">additives.\u003C\u002Fa> To achieve this, a base polymer such as (e.g., \u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS,\u003C\u002Fa> \u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa>, etc.) is combined with additives, fillers, or fibers. This process is called compounding. The goal is to improve existing material properties or create new functions.\u003C\u002Fp>\u003Cp>Fiber-reinforced compounds such as GMT or LFT are primarily used in organic sheet technology. This article focuses on compounds for traditional plastic deep drawing. The focus is on functional additives that enhance the performance of standard plastics\u003C\u002Fp>\u003Ch3>Standard plastic vs. compound: What's the difference?\u003C\u002Fh3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Standard Plastic\u003C\u002Fth>\u003Cth>Plastic Compound\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>consists of pure polymer\u003C\u002Ftd>\u003Ctd>contains additives or fillers\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>limited properties\u003C\u002Ftd>\u003Ctd>properties that can be specifically tailored\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>less expensive\u003C\u002Ftd>\u003Ctd>more expensive, but higher-performance\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Universally applicable\u003C\u002Ftd>\u003Ctd>Optimized for specific applications\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Standard plastics are “all-rounders”, compounds are specialists. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>Which plastics are typically compounded?\u003C\u002Fh3>\u003Cp>Many common thermoplastics can be further developed into compounds:\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Material\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Application\u003C\u002Fstrong>\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fasa-plastic\">ASA\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>robust applications\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fhd-pe-plastic\">HD-PE\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>cost-effective solutions\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpmma-plastic\">PMMA\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>high transparency and strength\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PET-A\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-g-plastic\">PET-G\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>ideal for packaging\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fstaging.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS\u003C\u002Fa> \u002F \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpvc-plastic\">PVC\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Versatile for use in technical and industrial applications\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 For more information on the various plastics, please see our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\">Material Guide 1\u003C\u002Fa> and \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-2\">Material Guide 2.\u003C\u002Fa> \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>Why are plastic additives used?\u003C\u002Fh2>\u003Cp>Plastic additives are used to specifically improve the properties of plastics. Typical modifications include:\u003C\u002Fp>\u003Cul>\u003Cli>higher mechanical strength\u003C\u002Fli>\u003Cli>better UV resistance\u003C\u002Fli>\u003Cli>reduced friction\u003C\u002Fli>\u003Cli>electrical conductivity or insulation\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Accordingly, plastic additives are used to specifically influence mechanical, thermal, and chemical properties. Without them, many technical applications would not be feasible at all.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:472\u002F313;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCompounds_Blau_in_Hand_c27b90b22e.webp\" alt=\"Compounds Blau in Hand\" width=\"472\" height=\"313\">\u003C\u002Ffigure>\u003Ch2>What is compounding? The manufacturing process explained simply\u003C\u002Fh2>\u003Cp>The term “compounding” refers to the industrial process of material preparation. In compounding, polymers and additives are processed in several steps.\u003C\u002Fp>\u003Col>\u003Cli>Dosing of raw materials\u003C\u002Fli>\u003Cli>Melting of the plastic\u003C\u002Fli>\u003Cli>Mixing and dispersing of additives\u003C\u002Fli>\u003Cli>Degassing of the melt\u003C\u002Fli>\u003Cli>Granulation to produce the finished compound\u003C\u002Fli>\u003C\u002Fol>\u003Ch3>1. Dosing of raw materials\u003C\u002Fh3>\u003Cp>This involves precisely determining which components are needed and in what quantities:\u003C\u002Fp>\u003Cul>\u003Cli>Base polymer (e.g., PP or ABS)\u003C\u002Fli>\u003Cli>Additives (e.g., UV protection, flame retardants)\u003C\u002Fli>\u003Cli>Fillers\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Important: Even small deviations can significantly alter the material properties. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>2. Melting the Plastic\u003C\u002Fh3>\u003Cp>The base material is heated in a machine, usually an extruder (see \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fplastic-extrusion\">Plastic Extrusion\u003C\u002Fa>), until it melts. You can think of this as melting plastic pellets into a viscous mass. In this state, the material can be processed optimally.\u003C\u002Fp>\u003Ch3>3. Mixing and dispersing the additives\u003C\u002Fh3>\u003Cp>The additives are now incorporated into the plastic melt. It is crucial that:\u003C\u002Fp>\u003Cul>\u003Cli>all components are evenly distributed\u003C\u002Fli>\u003Cli>no lumps or variations in concentration occur\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This step determines the final quality of the plastic compound.\u003C\u002Fp>\u003Ch3>4. Degassing\u003C\u002Fh3>\u003Cp>During the process, undesirable components may form, e.g.:\u003C\u002Fp>\u003Cul>\u003Cli>trapped air\u003C\u002Fli>\u003Cli>moisture\u003C\u002Fli>\u003Cli>volatile substances\u003C\u002Fli>\u003C\u002Ful>\u003Cp>These are specifically removed to ensure material quality.\u003C\u002Fp>\u003Ch3>5. Extrusion and pelletizing\u003C\u002Fh3>\u003Cp>The finished plastic mixture is then extruded from the machine and cooled. It is then cut into small, uniform pellets. This granulate is the actual “compound” that is later processed further.\u003C\u002Fp>\u003Ch2>What types of plastic compounds are there?\u003C\u002Fh2>\u003Cp>Plastic compounds can be distinguished by the type of additives used.\u003C\u002Fp>\u003Ch3>Additive-based compounds\u003C\u002Fh3>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:25%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_esd_schutz_a9091d2887.webp\" alt=\"Abdeckung ESD Schutz\" width=\"1299\" height=\"1299\">\u003Cfigcaption>Plastic housing with ESD protection\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>Additive-based compounds are primarily used for functional modification. In this process, substances are added to the plastic to specifically produce certain effects. For example, antistatic agents reduce electrostatic charge and provide \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fesd-trays-aus-kunststoff-einsatz-und-vorteile\">ESD protection,\u003C\u002Fa> while flame retardants improve fire resistance.\u003C\u002Fp>\u003Cp>Stabilizers protect the plastic from UV radiation or thermal aging, and lubricants ensure better processability and lower friction.\u003C\u002Fp>\u003Ch3>Filler-based compounds\u003C\u002Fh3>\u003Cp>Filler-based compounds are primarily aimed at mechanical optimization. Mineral fillers such as calcium carbonate or talc increase stiffness and improve dimensional stability. At the same time, they can reduce costs by partially replacing the more expensive base polymer. Carbon black is also used to increase UV resistance and extend the service life of components used outdoors.\u003C\u002Fp>\u003Ch2>When is it worth using plastic compounds?\u003C\u002Fh2>\u003Cp>Plastic compounds are a good choice when standard materials are not sufficient. Typical applications include, for example:\u003C\u002Fp>\u003Cul>\u003Cli>High mechanical stress\u003C\u002Fli>\u003Cli>UV or weather exposure\u003C\u002Fli>\u003Cli>Electrical requirements (ESD, insulation)\u003C\u002Fli>\u003Cli>Temperature resistance\u003C\u002Fli>\u003Cli>Long service life required\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Rule of thumb: The more specific the requirements, the more worthwhile it is to use a compound. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>Sustainability of Plastic Compounds\u003C\u002Fh2>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:25%;\">\u003Cimg style=\"aspect-ratio:1299\u002F1299;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fabdeckung_rezyklat_01_475a7ab964.webp\" alt=\"abdeckung rezyklat\" width=\"1299\" height=\"1299\">\u003C\u002Ffigure>\u003Cp>Plastic compounding enables the use of \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fwas-ist-rezyklat-moeglichkeiten-im-kunststoff-recycling-und-abgrenzung-zu-neuware\">recycled materials\u003C\u002Fa> and improves their properties for more demanding applications. They reduce material consumption through lighter components and extend service life.\u003C\u002Fp>\u003Cp>At the same time, fluctuating material qualities and complex blends can make recycling more difficult. Higher development and material costs are also possible, which is why a targeted and application-oriented material selection is crucial.\u003C\u002Fp>\u003Ch2>Practical Applications of Plastic Compounds\u003C\u002Fh2>\u003Cp>Plastic compounds are used wherever standard materials are not sufficient.\u003C\u002Fp>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fthermoformed-parts-for-automotive\">Automotive Industry\u003C\u002Fa>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:1600\u002F1600;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FAutomatisierungstray_ESD_a5d39bc85b.webp\" alt=\"Automatisierungstray ESD\" width=\"1600\" height=\"1600\">\u003Cfigcaption>Example of an ESD-Tray\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cul>\u003Cli>Interior trim with high impact resistance\u003C\u002Fli>\u003Cli>Temperature-resistant housings and covers in the engine compartment\u003C\u002Fli>\u003Cli>Battery housings for e-mobility\u003C\u002Fli>\u003Cli>Airflow components and technical mounts\u003C\u002Fli>\u003Cli>UV-resistant exterior components\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Fmedical-pharmaceutical-applications\">Medical Technology\u003C\u002Fa>\u003C\u002Fh3>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fprodukte\u002Fmedizintechnik-gehaeuse-aus-kunststoff\">Housings for medical devices\u003C\u002Fa>\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fmedical-blister-packaging\">Sterile blister packs\u003C\u002Fa> and trays\u003C\u002Fli>\u003Cli>Disposable products such as trays or holders\u003C\u002Fli>\u003Cli>Components with high hygiene requirements\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Findustries\u002Felectronics\">Electronics\u003C\u002Fa>\u003C\u002Fh3>\u003Cul>\u003Cli>Flame-retardant enclosures\u003C\u002Fli>\u003Cli>Insulating components for electrical systems\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fprodukte\u002Fesd-werkstuecktraeger-fuer-elektronik\">ESD trays\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Protective enclosures for sensors and control systems\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>Construction Industry\u003C\u002Fh3>\u003Cul>\u003Cli>Weather-resistant facade elements\u003C\u002Fli>\u003Cli>Outdoor covers and protective enclosures\u003C\u002Fli>\u003Cli>Insulation components with insulating properties\u003C\u002Fli>\u003Cli>Cable ducts and technical installation systems\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>Advantages and Disadvantages of Plastic Compounds\u003C\u002Fh2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of Plastic Compounds\u003C\u002Fth>\u003Cth>Disadvantages of Plastic Compounds\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>Customized properties\u003C\u002Ftd>\u003Ctd>Higher material costs\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Higher performance than standard plastics\u003C\u002Ftd>\u003Ctd>More complex processing\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Wide range of applications\u003C\u002Ftd>\u003Ctd>Longer development time\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>Combination of multiple functions in a single material\u003C\u002Ftd>\u003Ctd> \u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Chr>\u003Ch2>Do you need plastic compounds for your project? Request a quote now!\u003C\u002Fh2>\u003Cp>Plastic compounds are a key component for high-performance \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">thermoformed plastic parts.\u003C\u002Fa> They allow materials to be precisely tailored to your requirements, whether you need higher strength, better UV resistance or special functions. Compounds transform standard plastics into true high-performance materials. Inquire now!\u003C\u002Fp>","what-are-plastic-compounds",{"id":892,"documentId":893,"createdAt":894,"updatedAt":895,"publishedAt":85,"locale":10,"title":896,"introduction":897,"content":898,"slug":899},987,"qk0kk2js6odata8ftgdiat40","2026-06-09T16:26:23.846Z","2026-06-23T11:51:53.711Z","Checklist: 10 Details a plastic thermoformer needs from you","You’re planning to source plastic thermoformed parts and want to submit a request for a quote. But what information does a thermoforming supplier really need to provide you with a meaningful quote? Incomplete requests lead to follow-up questions, delay the quoting process, and complicate the technical evaluation. If you provide the right information from the start, you’ll receive a reliable estimate faster and avoid unnecessary back-and-forth.","\u003Ch2>Information a Thermoformer Needs From You - The Most Important Points at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>CAD data or sketch:\u003C\u002Fstrong> Geometry and dimensions form the basis of every inquiry\u003C\u002Fli>\u003Cli>\u003Cstrong>Material and properties:\u003C\u002Fstrong> The type of plastic, ESD protection, or sterilizability determine the process\u003C\u002Fli>\u003Cli>\u003Cstrong>Quantity and order frequency:\u003C\u002Fstrong> One-time small batches or recurring deliveries require different tooling strategies\u003C\u002Fli>\u003Cli>\u003Cstrong>Application and installation situation:\u003C\u002Fstrong> The context of use shapes the geometry, tolerances, and post-processing\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>What does a Thermoformer Need for a Complete Inquiry?\u003C\u002Fh2>\u003Cp>A complete inquiry includes technical, project-related, and application-specific information. The following 10 details form the basis for an optimal project workflow.\u003C\u002Fp>\u003Ch3>1. CAD data, technical drawing, or sketch\u003C\u002Fh3>\u003Cp>The component geometry is the central starting point. Ideally, you should provide \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fconstruction-data-in-thermoforming\">3D CAD data\u003C\u002Fa> in STEP format or a dimensioned 2D drawing in PDF format. If no CAD data is available, sketches with rough dimensions, photos of a reference part, or a verbal description will also help.\u003C\u002Fp>\u003Cp>Based on this, formary creates an initial design concept and checks for thermoformability. If you do not have your own design data, formary will handle the creation based on your requirements and our many years of experience in developing thermoformable geometries.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 STEP files are platform-independent and enable seamless data exchange between different CAD systems. PDF drawings should include all relevant dimensions, tolerances, and sectional views. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>2. Dimensions\u003C\u002Fh3>\u003Cfigure class=\"image image-style-side\">\u003Cimg style=\"aspect-ratio:217\u002F217;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FESD_Trays_Abmessungen_2ddfd8d479.png\" alt=\"ESD-Trays_Abmessungen\" width=\"217\" height=\"217\">\u003C\u002Ffigure>\u003Cp>If CAD data is not available, at least the length, width, and height of the component are required. For trays with nests, the following information should also be provided:\u003C\u002Fp>\u003Cul>\u003Cli>Number of nests\u003C\u002Fli>\u003Cli>Dimensions of the component to be inserted\u003C\u002Fli>\u003Cli>Desired orientation within the nest\u003C\u002Fli>\u003Cli>Recessed handles or removal aids\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Wall thicknesses, radii, holes, or cutouts should also be communicated as early as possible to avoid follow-up inquiries.\u003C\u002Fp>\u003Ch3>3. Material and Material Properties\u003C\u002Fh3>\u003Cp>The choice of plastic affects the process, tool design, and costs. Specify the desired \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">material \u003C\u002Fa>or describe the required properties. Typical material information includes the type of plastic, the thickness of the starting sheet, the desired color, and special properties such as ESD protection, UV resistance, food suitability, or temperature resistance.\u003C\u002Fp>\u003Cp>If you are unsure which material is suitable, describe the application. Based on this, formary will suggest suitable plastics.\u003C\u002Fp>\u003Cfigure class=\"table\" style=\"width:74.14%;\">\u003Ctable class=\"ck-table-resized\">\u003Ccolgroup>\u003Ccol style=\"width:13.9%;\">\u003Ccol style=\"width:60.3%;\">\u003Ccol style=\"width:25.8%;\">\u003C\u002Fcolgroup>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Material\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>\u003Cstrong>Typical applications\u003C\u002Fstrong>\u003C\u002Fth>\u003Cth>Special characteristics\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Housing, workpiece carrier\u003C\u002Ftd>\u003Ctd>impactresistant, easy to work with\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS\u003C\u002Fa> \u003C\u002Ftd>\u003Ctd>Simple trays, displays\u003C\u002Ftd>\u003Ctd>costeffective, transparency possible\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PET-A\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>Blister packs, food packaging\u003C\u002Ftd>\u003Ctd>transparent, foodsafe\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>technical covers\u003C\u002Ftd>\u003Ctd>hightemperature resistant, durable\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa>\u003C\u002Ftd>\u003Ctd>chemicalresistant containers\u003C\u002Ftd>\u003Ctd>flexible, chemicalresistant\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Cp>\u003Cstrong>Tip:\u003C\u002Fstrong> In the formary \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">\u003Cu>Configurator\u003C\u002Fu>\u003C\u002Fa>, you can also get automated material recommendations based on your requirements.\u003C\u002Fp>\u003Ch3>4. Quantity and Order Frequency\u003C\u002Fh3>\u003Cp>The planned quantity is a key factor in selecting the right tooling. One-time small-batch runs require different solutions than recurring high-volume production. Relevant information includes the total quantity (one-time or recurring), the batch size per order, the planned delivery period, and the expected volume growth from prototype through small-batch runs to high-volume production.\u003C\u002Fp>\u003Cp>This information determines which \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Ftools-for-thermoformed-plastic-parts\">mold solution\u003C\u002Fa> makes economic sense. Small quantities can often be produced cost-effectively using 3D-printed molds or urethane molds. Larger production runs justify aluminum molds with a longer service life and higher precision.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Many inquiries do not specify clear quantities. This makes it much more difficult to assess the technical and financial aspects. Even rough estimates can be helpful when preparing a quote. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>5. Application and Intended Use\u003C\u002Fh3>\u003Cp>The intended use provides insight into the functional requirements that influence the design.\u003C\u002Fp>\u003Cp>\u003Cstrong>Typical applications:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Fesd-plastic-transport-packaging\">Transport\u003C\u002Fa> of sensitive components\u003C\u002Fli>\u003Cli>Storage and order picking\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-production-automation\">Automation\u003C\u002Fa> in production\u003C\u002Fli>\u003Cli>Protective packaging for shipping\u003C\u002Fli>\u003Cli>Retail display\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Depending on the application, different tolerances, surface qualities, stackability, or grip concepts may be required.\u003C\u002Fp>\u003Ch3>6. Installation Situation and Integration\u003C\u002Fh3>\u003Cp>If the thermoformed part is integrated into an assembly or interacts with other components, information regarding the installation situation is important.\u003C\u002Fp>\u003Cp>\u003Cstrong>Relevant questions:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Is the part screwed, clipped, or snapped into place?\u003C\u002Fli>\u003Cli>Are there defined mounting points?\u003C\u002Fli>\u003Cli>Must specific tolerances be maintained?\u003C\u002Fli>\u003Cli>Are assembly aids required?\u003C\u002Fli>\u003Cli>Does the part fit into an existing system?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Covers, housings, or technical components should always be considered within the context of the overall design. Unclear installation situations lead to rework after prototyping.\u003C\u002Fp>\u003Ch3>7. Special Requirements\u003C\u002Fh3>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:40.39%;\">\u003Cimg style=\"aspect-ratio:768\u002F768;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefzieh_Behaeltnis_Materialanforderungen_8cce261cfd.jpg\" alt=\"Tiefzieh_Behaeltnis_Materialanforderungen.jpg\" width=\"768\" height=\"768\">\u003C\u002Ffigure>\u003Cp>Special technical requirements should be communicated early on, as they affect material selection, tooling, and post-processing. Typical special requirements include\u003C\u002Fp>\u003Cul>\u003Cli>ESD protection for dissipating static charge\u003C\u002Fli>\u003Cli>Sterilizability via steam\u003C\u002Fli>\u003Cli>Gamma radiation or EtO\u003C\u002Fli>\u003Cli>Transparency or light transmission\u003C\u002Fli>\u003Cli>Chemical resistance to specific media\u003C\u002Fli>\u003Cli>FDA or REACH compliance\u003C\u002Fli>\u003Cli>Flame retardancy\u003C\u002Fli>\u003Cli>As well as UV resistance for outdoor applications.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Each of these requirements narrows down the choice of materials and may require additional testing or certifications.\u003C\u002Fp>\u003Ch3>8. Post-processing and Additional Processes\u003C\u002Fh3>\u003Cp>Many thermoformed parts require further processing steps after forming. Standard procedures include \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fseparating\">punching or milling\u003C\u002Fa> following the thermoforming process.\u003C\u002Fp>\u003Cp>\u003Cstrong>Additional post-processing steps:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fsurface-treatment\u002Fprinting\">Printing\u003C\u002Fa> or labeling\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fconnecting\u002Fbonding\">Bonding\u003C\u002Fa> of multiple components\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fpost-processing-methods\u002Fconnecting\">Assembly\u003C\u002Fa> of clips, closures, or handles\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image_resized image-style-side\" style=\"width:63.62%;\">\u003Cimg style=\"aspect-ratio:2000\u002F1498;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefgezogene_Kunststoffwanne_rot_nachlackiert_77d2c1c31f.webp\" alt=\"Tiefgezogene Kunststoffwanne rot nachlackiert\" width=\"2000\" height=\"1498\">\u003C\u002Ffigure>\u003Cp>If you require such additional services, please mention them in your inquiry. As a full-service provider, formary offers all post-processing steps under one roof.\u003C\u002Fp>\u003Ch3>9. Delivery Date and Schedule\u003C\u002Fh3>\u003Cp>The desired delivery time influences the choice of tooling and the project workflow. Relevant time-related details include the desired delivery date for samples, the planned start of series production, the urgency (standard lead time or express), and the call-off schedule for recurring deliveries (weekly, monthly, quarterly).\u003C\u002Fp>\u003Cp>Typically, the lead time is approximately 3–5 weeks from approval to delivery. Shorter lead times are possible for simple geometries and available materials.\u003C\u002Fp>\u003Ch3>10. Budget or Target Price\u003C\u002Fh3>\u003Cp>A rough budget estimate helps in selecting the right solution. If you have a target price or a price ceiling, formary can specifically suggest tooling variants and manufacturing options that fit within your budget.\u003C\u002Fp>\u003Cp>This speeds up the decision-making process and avoids unnecessary iterations. If no budget is specified, formary will prepare a transparent quote based on the technical requirements.\u003C\u002Fp>\u003Ch2>How to Submit Your Request to formary\u003C\u002Fh2>\u003Cp>formary offers three ways to submit your request:\u003C\u002Fp>\u003Ch3>1. Use the configurator\u003C\u002Fh3>\u003Cp>In the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">configurator\u003C\u002Fa>, you can enter all relevant details step by step. The system guides you through the most important points and ensures that no essential information is missing. You will receive an initial quote within 24 hours.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKonfigurator_Mockup_72fabb364c.png\" alt=\"Konfigurator Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>2. Using the 3D Tray Generator\u003C\u002Fh3>\u003Cp>If you need a custom tray for a specific component, you can use the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa> to create a suitable tray design directly. Upload your component, define the number of nests and orientation, as well as other specifications that are important for your requirements.\u003C\u002Fp>\u003Cp>If you are satisfied with your generated 3D tray, you can submit a request directly through the 3D Tray Generator.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_Generator_Mockup_2_780e8a9306.webp\" alt=\"3D Tray Generator Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch3>3. Direct Inquiry by Email\u003C\u002Fh3>\u003Cp>You can also send all information to formary by email. Attach CAD data, sketches, or photos and describe your project. formary will review the documents and get back to you promptly with a quote or follow-up questions.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle> .c-container { border: 2px solid #15A9A4; padding: 10px; margin: 10px; border-radius: 10px; } .c-container { margin: 0; } \u003C\u002Fstyle> \u003Cdiv class=\"c-container\"> \u003Cp> 💡 Use the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\" target=\"_blank\">Configurator\u003C\u002Fa>, once you have all the necessary data. The \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\" target=\"_blank\">3D Tray Generator\u003C\u002Fa> is ideal if you need a tray for a known component. It’s worth sending an email inquiry if your project isn’t fully defined yet. \u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>What Happens After You Submit Your Inquiry?\u003C\u002Fh2>\u003Cp>Once we receive your inquiry, your project will go through the following steps:\u003C\u002Fp>\u003Col>\u003Cli>\u003Cstrong>Inquiry review:\u003C\u002Fstrong> formary checks your information for completeness and technical feasibility.\u003C\u002Fli>\u003Cli>\u003Cstrong>Quotation:\u003C\u002Fstrong> You will receive a quote with pricing, delivery time, and tooling options.\u003C\u002Fli>\u003Cli>\u003Cstrong>Design or data adaptation:\u003C\u002Fstrong> formary creates the design data or adapts your CAD data for thermoforming.\u003C\u002Fli>\u003Cli>\u003Cstrong>Approval of design data:\u003C\u002Fstrong> You review the drawing and approve it.\u003C\u002Fli>\u003Cli>\u003Cstrong>Sampling:\u003C\u002Fstrong> Depending on the project requirements, formary produces samples using 3D-printed, urethane, or aluminum tools.\u003C\u002Fli>\u003Cli>\u003Cstrong>Series production:\u003C\u002Fstrong> Series production begins after the samples have been successfully approved.\u003C\u002Fli>\u003C\u002Fol>\u003Cp>Every step is supported by a dedicated contact person who answers technical questions and coordinates the process.\u003C\u002Fp>\u003Chr>\u003Ch2>Conclusion: Providing Complete Information Speeds Up Your Project\u003C\u002Fh2>\u003Cp>A well-prepared inquiry saves time, prevents misunderstandings, and leads to a reliable quote more quickly. Key details such as CAD data, material, quantity, and application form the basis for any professional quote.\u003C\u002Fp>\u003Cp>formary also supports you with technical advice and design services even for incomplete inquiries. The more precise your details, the better formary can address your specific requirements.\u003C\u002Fp>","checklist-details-for-thermoformers",{"id":901,"open_graph_title":556,"open_graph_description":902,"title":556,"description":902},2148,"Thermoformed parts in practice: ✓ Insights into thermoforming ✓ Useful information about plastic thermoforming ▶ We explain all aspects of thermoforming.",[904],{"id":905,"documentId":553,"createdAt":906,"updatedAt":907,"publishedAt":85,"locale":128,"title":908,"slug":909,"description":910},25,"2026-01-08T23:02:59.586Z","2026-01-26T08:56:15.473Z","Tiefziehteile in der Praxis","tiefziehteile-in-der-praxis","Alle Einblicke in die Praxis des Thermoformings. Nützliche Hinweise, was gilt es zu beachten? Hier finden Sie Einträge zu allen Aspekten des Thermoformings.",[912,933],{"__component":913,"id":914,"title":915,"variant":289,"first_accordion_open":425,"accordions":916},"page-template.accordion",1639,"Frequently Asked Questions about the DfM Analysis",[917,921,925,929],{"id":918,"title":919,"content":920},10587,"What is Design for Manufacturing?","\u003Cp>Design for Manufacturing (DfM) means designing products so they can be manufactured efficiently, cost-effectively, and without errors. The goal is to consider all manufacturing aspects right from the design stage.\u003C\u002Fp>",{"id":922,"title":923,"content":924},10588,"What does DfM mean?","\u003Cp>DfM stands for “Design for Manufacturing” and describes a design approach that optimizes manufacturability and production costs from the very beginning.\u003C\u002Fp>\n\n\u003Cp>For more information on how you can reduce costs, please refer to the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fguide-to-cost-reduction-in-thermoforming\">Guide to Cost Reduction in Thermoforming.\u003C\u002Fa>\u003C\u002Fp>",{"id":926,"title":927,"content":928},10591,"How do I carry out a technical feasibility check for a plastic thermoformed part?","\u003Cp> The feasibility of a plastic thermoformed part can be assessed based on a few key criteria: requirements, geometry, material, tooling, process, tolerances and cost-effectiveness. \u003C\u002Fp> \u003Cul> \u003Cli> \u003Cstrong>Define the requirements:\u003C\u002Fstrong> Clarify function, quantity, process, application area, tolerances, post-processing and material specifications. \u003C\u002Fli> \u003Cli> \u003Cstrong>Check the geometry:\u003C\u002Fstrong> Evaluate draw ratio, depth, draft angles, radii, undercuts and wall thickness distribution. \u003C\u002Fli> \u003Cli> \u003Cstrong>Select the material:\u003C\u002Fstrong> Assess suitable plastics such as ABS, HIPS, PET-G, PMMA or HD-PE. PP, PC and technical blends are often more demanding. \u003C\u002Fli> \u003Cli> \u003Cstrong>Evaluate the tooling concept:\u003C\u002Fstrong> Consider tool type, venting, temperature control and possible undercuts. \u003C\u002Fli> \u003Cli> \u003Cstrong>Secure the manufacturing process:\u003C\u002Fstrong> For complex parts, simulate wall thicknesses, wrinkle formation, material flow and local overstretching. \u003C\u002Fli> \u003Cli> \u003Cstrong>Check cost-effectiveness:\u003C\u002Fstrong> Evaluate tooling costs, cycle time, material utilization, trimming ratio, automation and scrap risk. \u003C\u002Fli> \u003Cli> \u003Cstrong>Carry out prototyping:\u003C\u002Fstrong> Sample parts help validate appearance, warpage, assembly, stability and actual wall thicknesses before series production. \u003C\u002Fli> \u003C\u002Ful> \u003Cp> A thermoformed part becomes particularly critical when it has very deep or narrow geometries, sharp corners, missing draft angles, tight injection-molding tolerances, many undercuts, strongly varying wall thicknesses or extreme flatness requirements. \u003C\u002Fp>",{"id":930,"title":931,"content":932},10592,"Which Design for Manufacturing rules apply to plastic thermoforming?","\u003Cp> In Design for Manufacturing for plastic thermoformed parts, the main focus is on wall thickness control, radii, draft angles, draw ratio and material flow. \u003C\u002Fp> \u003Cul> \u003Cli> \u003Cstrong>Aim for uniform wall thicknesses:\u003C\u002Fstrong> Check deep areas, corners and areas with high material stretch early, as the material locally thins out during thermoforming. \u003C\u002Fli> \u003Cli> \u003Cstrong>Use large radii:\u003C\u002Fstrong> Avoid sharp edges, as they can lead to material thinning, cracks and poor reproducibility. \u003C\u002Fli> \u003Cli> \u003Cstrong>Plan for draft angles:\u003C\u002Fstrong> Industry standard for female molds: 1.5–2°; industry standard for male molds: 4–6°. \u003C\u002Fli> \u003Cli> \u003Cstrong>Limit the draw ratio:\u003C\u002Fstrong> Excessive draw ratios increase the risk of wrinkles, severe thinning and material failure. \u003C\u002Fli> \u003Cli> \u003Cstrong>Prefer uniform depths:\u003C\u002Fstrong> Smooth transitions, symmetrical shapes and consistent draw depths improve material flow. \u003C\u002Fli> \u003Cli> \u003Cstrong>Use ribs appropriately:\u003C\u002Fstrong> Ribs increase stiffness, but should be designed with wide geometries and large transition radii. \u003C\u002Fli> \u003Cli> \u003Cstrong>Design with the tooling in mind:\u003C\u002Fstrong> Temperature control, vacuum holes, venting and tool material influence quality and costs. \u003C\u002Fli> \u003C\u002Ful>",{"__component":430,"id":934,"title":935,"variant":289,"cta_button":85,"blogarticles":936,"style":941},902,"Further Resources",[937,938,939,940],{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631},{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},{"id":713,"documentId":714,"createdAt":715,"updatedAt":716,"publishedAt":85,"locale":10,"title":717,"introduction":718,"content":719,"slug":720},{"id":678,"documentId":679,"createdAt":680,"updatedAt":681,"publishedAt":85,"locale":10,"title":682,"introduction":683,"content":684,"slug":685},{"id":942,"background":943,"border":85},3440,"white",[945],{"id":946,"documentId":436,"createdAt":947,"updatedAt":948,"publishedAt":85,"locale":128,"title":949,"introduction":950,"content":951,"slug":952},288,"2026-01-08T23:07:33.491Z","2026-05-26T15:47:03.376Z","Design for Manufacturing (DfM): Leitfaden für fertigungsgerechtes Design","Mit der neuen Design for Manufacturing Analyse von formary gibt es jetzt die Möglichkeit, CAD-Daten in Sekundenschnelle auf Tiefziehbarkeit zu prüfen - und so potenzielle Fehlerquellen früh zu erkennen, bevor sie teuer werden. Welche Funktionen die DfM-Software bietet und was das Design for Manufacturing Prinzip beinhaltet, erfahren Sie im Beitrag.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Design for Manufacturing - Das Wichtigste in Kürze\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>Design for Manufacturing (DfM) bedeutet, Produkte so zu gestalten, dass sie einfach, wirtschaftlich und fehlerarm gefertigt werden können.\u003C\u002Fli>\u003Cli>Mit einer Design for Manufacturing-Analyse erkennen Sie Fertigungsprobleme schon in der Konstruktionsphase.\u003C\u002Fli>\u003Cli>Das neue DfM-Tool von formary ermöglicht die automatisierte Analyse Ihrer 3D-Modelle und zwar schnell, präzise und kostenlos im Browser.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Direkt zur DfM-Analyse: \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">formary.de\u002F3d-services\u002Fdfm-analyse\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was ist Design for Manufacturing?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cstrong>DfM Bedeutung:\u003C\u002Fstrong> Design for Manufacturing, Design for Manufacturability (DfM) oder auch “fertigungsgerechtes Design” bezeichnet einen Konstruktionsansatz, bei dem Bauteile so gestaltet werden, dass sie einfach, effizient und kostengünstig gefertigt werden können bei gleichzeitig hoher Qualität.\u003C\u002Fp>\u003Cp>\u003Cstrong>Kurz gesagt:\u003C\u002Fstrong> DfM sorgt dafür, dass schon beim Design klar ist, wie das Produkt später gefertigt werden kann und Kunden dabei Zeit und Geld sparen.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Wie funktioniert Design for Manufacturing?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Design for Manufacturing funktioniert, indem schon in der Konstruktionsphase überprüft wird, ob ein Bauteil produzierbar ist. Dazu gibt es klare Fertigungsregeln und Kriterien wie Wandstärken, Radien oder Entformbarkeit:\u003C\u002Fp>\u003Col>\u003Cli>Analyse der Geometrie auf Fertigbarkeit\u003C\u002Fli>\u003Cli>Erkennen kritischer Stellen (z. B. zu dünne Wandstärken)\u003C\u002Fli>\u003Cli>Anpassen des Designs zur Optimierung\u003C\u002Fli>\u003Cli>Validierung und Freigabe für den Fertigungsprozess\u003C\u002Fli>\u003C\u002Fol>\u003Ch3>\u003Cspan style=\"color:#005250;\">Die 5 Design for Manufacturing Prinzipien\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Design for Manufacturing basiert auf fünf zentralen Prinzipien, die helfen, Fertigungsprobleme schon in der Konstruktionsphase zu lösen.\u003C\u002Fp>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Design for Manufacturing Prinzip\u003C\u002Fth>\u003Cth>Anwendung von DfM im Entwicklungsprozess\u003C\u002Fth>\u003Cth>Probleme, die mit Design for Manufacturing gelöst werden\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>1️⃣ Fehlervermeidung im Design\u003C\u002Ftd>\u003Ctd>Potenzielle Fehlerquellen früh erkennen und eliminieren\u003C\u002Ftd>\u003Ctd>Weniger Reklamationen, höhere Qualität\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>2️⃣ Fertigungsgerechtes Design\u003C\u002Ftd>\u003Ctd>Geeignete Verfahren und Materialien berücksichtigen\u003C\u002Ftd>\u003Ctd>Verbesserte Herstellbarkeit, reduzierte \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fstueckkosten-und-werkzeugkosten-im-tiefziehen\">Produktionskosten\u003C\u002Fa>\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>3️⃣ Teileanzahl reduzieren\u003C\u002Ftd>\u003Ctd>Möglichst wenige Einzelteile entwerfen\u003C\u002Ftd>\u003Ctd>Weniger Montageaufwand, geringere Fehlerquellen\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>4️⃣ Standardisierte Komponenten\u003C\u002Ftd>\u003Ctd>Standardteile statt Sonderanfertigungen verwenden\u003C\u002Ftd>\u003Ctd>Kürzere Lieferzeiten, geringere Kosten, einfachere Beschaffung\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>5️⃣ Modularisierung des Designs\u003C\u002Ftd>\u003Ctd>Bauteile in austauschbare Module aufteilen\u003C\u002Ftd>\u003Ctd>Bessere Wartbarkeit, einfachere Variantenfertigung\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Vorteile von Design for Manufacturing\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Die DfM-Analyse bietet aufgrund seiner Grundprinzipien zahlreiche Vorteile:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Frühzeitige Fehlererkennung:\u003C\u002Fstrong> Kritische Stellen werden schon im CAD-Modell identifiziert\u003C\u002Fli>\u003Cli>\u003Cstrong>Kostensenkung:\u003C\u002Fstrong> Vermeidung teurer Nacharbeiten und Reklamationen\u003C\u002Fli>\u003Cli>\u003Cstrong>Effizientere Prozesse:\u003C\u002Fstrong> Weniger Rückfragen und Wartezeiten im Entwicklungsprozess\u003C\u002Fli>\u003Cli>\u003Cstrong>Verbesserte Qualität:\u003C\u002Fstrong> Bessere Umsetzbarkeit und Reproduzierbarkeit in der Serie\u003C\u002Fli>\u003Cli>\u003Cstrong>Planungssicherheit:\u003C\u002Fstrong> Klare Kommunikation mit Fertigung und Werkzeugbau\u003C\u002Fli>\u003Cli>\u003Cstrong>Anpassbar für verschiedene Fertigungsverfahren:\u003C\u002Fstrong> Egal ob Spritzguss, 3D-Druck oder \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Ftiefziehen-kunststoff\">Kunststoff Tiefziehen:\u003C\u002Fa> DfM unterstützt alle gängigen Herstellungsverfahren.\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Was bedeutet die DfM-Analyse für das Tiefziehverfahren in der Praxis?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKunststoffabdeckung_ac9d53be5c.png\" alt=\"Längliche Kunststoffabdeckung in orange\">\u003C\u002Ffigure>\u003Cp>Beim Entwurf eines Kunststoff Tiefziehteils wie zum Beispiel bei \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Floesungen\u002Fkunststoff-abdeckungen-gehaeuse\">Kunststoffabdeckungen\u003C\u002Fa> oder \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Floesungen\u002Fkunststoff-behaeltnisse\">Kunststoffbehältnissen\u003C\u002Fa> bedeutet das zum Beispiel:\u003C\u002Fp>\u003Cul>\u003Cli>Wandstärken optimieren, um gleichmäßige Materialverteilung sicherzustellen\u003C\u002Fli>\u003Cli>Radien so gestalten, dass sie sich problemlos tiefziehen lassen\u003C\u002Fli>\u003Cli>Bauteile modular aufbauen, um Varianten zu ermöglichen\u003C\u002Fli>\u003Cli>Standardisierte Halterungen oder Befestigungen einsetzen\u003C\u002Fli>\u003Cli>Die Entformschrägen für einfache Entnahme aus dem Werkzeug berücksichtigen\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ Was Sie bei der Konstruktion von Kunststoff Tiefziehteilen noch beachten müssen, erfahren Sie in unserem Beitrag \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fgestaltungsregeln-bei-kunststoff-tiefziehteilen\"> Gestaltungsregeln für Kunststoff Tiefziehteile.\u003C\u002Fa> \u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was sind die Herausforderungen und Nachteile bei DfM?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Obwohl Design for Manufacturing viele Vorteile bietet, gibt es typische Herausforderungen in der Praxis:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Erfordert oft viel Erfahrung:\u003C\u002Fstrong> Konstrukteure müssen komplexe Fertigungsregeln berücksichtigen\u003C\u002Fli>\u003Cli>\u003Cstrong>Zeitaufwändige manuelle Prüfungen:\u003C\u002Fstrong> Ohne Software-Tools müssen Wandstärken, Radien und Entformschrägen händisch analysiert werden\u003C\u002Fli>\u003Cli>\u003Cstrong>Fehlerrisiko:\u003C\u002Fstrong> Menschliche Einschätzungen sind fehleranfällig und können zu teuren Nacharbeiten führen\u003C\u002Fli>\u003Cli>\u003Cstrong>Kommunikationsprobleme:\u003C\u002Fstrong> Ohne klare Visualisierung entstehen Missverständnisse zwischen Konstruktion und Werkzeugbau\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">Die Lösung: DfM-Analyse von Kunststoff Tiefziehteilen in Sekunden\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-side image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDf_M_Analyse_Mockup_1aee8cf644.webp\" alt=\"DfM-Analyse-Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Cp>Laden Sie Ihre Tiefziehteil-Daten hoch und unsere \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">DfM-Software\u003C\u002Fa> wertet aus, ob dieses so hergestellt werden kann oder welche Geometrien aus technischen, funktionalen oder Kostengründen umgestaltet werden müssen. Diese können durch Sie oder uns übernommen werden.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">So funktioniert die DfM-Analyse:\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>STEP-Datei hochladen\u003C\u002Fli>\u003Cli>Automatische Analyse in ca. 60 Sekunden\u003C\u002Fli>\u003Cli>Farbkodierte Ergebnisse für:\u003Cul>\u003Cli>Wandstärkenverteilung\u003C\u002Fli>\u003Cli>Radien\u003C\u002Fli>\u003Cli>Kanten und Entformschrägen\u003C\u002Fli>\u003Cli>Verstreckungsverhältnis\u003C\u002Fli>\u003Cli>Engstellen und Details\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Fol>\u003Cp>Alle Details erklären wir Ihnen in unserem Video: \u003C\u002Fp>\u003Cfigure class=\"media\">\u003Coembed url=\"https:\u002F\u002Fyoutu.be\u002Fs6GyeKqi6lw?si=ePBCF8sZwbK7tCFd\">\u003C\u002Foembed>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Vorteile des DfM-Tools\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Automatisierte Analyse in Sekunden\u003C\u002Fli>\u003Cli>Farbkodiert und visuell verständlich\u003C\u002Fli>\u003Cli>Keine Wartezeiten oder manuelle Rückfragen\u003C\u002Fli>\u003Cli>Fehler frühzeitig erkennen und Kosten senken\u003C\u002Fli>\u003Cli>Direkt im Browser nutzbar\u003C\u002Fli>\u003Cli>Kein Expertenwissen notwendig\u003C\u002Fli>\u003Cli>Grundlage für eine reibungslose Abstimmung mit dem Werkzeugbau.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ Wichtig ist natürlich trotzdem, dass die \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ffreigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten\"> Konstruktionsdaten\u003C\u002Fa> bei der Freigabe gründlich geprüft werden, um spätere Fehler im Design zu vermeiden.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Design for Manufacturing für Kunststoff Tiefziehteile - Jetzt einfacher als je zuvor\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Design for Manufacturing sorgt dafür, dass Ihre Produkte von Anfang an fertigbar sind. Mit unserer kostenlosen \u003Cstrong>DfM-Analyse\u003C\u002Fstrong> prüfen Sie Ihr Design in rund 60 Sekunden - für weniger Fehler, niedrigere Kosten und reibungslose Workflows. \u003Ca href=\"https:\u002F\u002Fmeetings.hubspot.com\u002Fmoritz-bittner-formary\u002Fdfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=69376d09-d796-4f3c-9d5e-ff6833d70b23\">Buchen Sie jetzt Ihre Demo!\u003C\u002Fa>\u003C\u002Fp>","design-for-manufacturing",{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604,"cover":954,"seo":1005,"blog_author":1060,"blogcategory":1068,"inline_hubspot_form":85,"blocks":1112,"localizations":1159},{"id":955,"documentId":956,"name":957,"alternativeText":601,"caption":16,"width":363,"height":213,"formats":958,"hash":999,"ext":304,"mime":307,"size":1000,"url":1001,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1002,"updatedAt":1003,"publishedAt":1004},2173,"soisr6w17vtqjxa0ubt3f4kb"," Design Guidelines for Plastic Thermoformed Parts – Top 13 Tips for Plastic-Optimized Construction Blog Banner 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Asked Questions About the Design of Plastic Thermoformed Parts",[1117,1121,1125,1129,1133,1137],{"id":1118,"title":1119,"content":1120},9434,"What radii are suitable for deep-drawing in plastic deep-drawn parts?","\u003Cp>Radii facilitate deep drawing and prevent cracks and wrinkles. Minimum radius for radii: 1.5 mm; for sharp edges, at least the material thickness.\u003C\u002Fp>",{"id":1122,"title":1123,"content":1124},9435,"What are wall slopes, and why are they needed?","\u003Cp>Wall drafts (at least 2°) facilitate demolding and prevent surface marks. Standard: 1.5–2° for negative molds, 4–6° for positive molds.\u003C\u002Fp>",{"id":1126,"title":1127,"content":1128},9436,"Positive or negative framing: what's the difference?","\u003Cp>Positive sections taper toward the edges, while negative sections taper toward the bottom. Positive shapes are generally more advantageous in terms of aspect ratio and material weaknesses.\u003C\u002Fp>",{"id":1130,"title":1131,"content":1132},9437,"Why should fillets and undercuts be taken into account?","\u003Cp>Smooth transitions prevent wrinkles and tears. Undercuts make demolding difficult and should be reduced or redesigned.\u003C\u002Fp>",{"id":1134,"title":1135,"content":1136},9438,"What role do material selection and shrinkage play?","\u003Cp>Soft plastics shrink more and deform after demolding. Harder materials offer greater dimensional stability and better tolerances.\u003C\u002Fp>",{"id":1138,"title":1139,"content":1140},9439,"What should you keep in mind regarding engravings and mounting points?","\u003Cp>Engravings: recessed (negative) ones are less expensive, while raised (positive) ones are more expensive. Fastening points such as screws or rivets should be planned early on, depending on the load and intended use.\u003C\u002Fp>",{"__component":430,"id":1142,"title":1143,"variant":289,"cta_button":85,"blogarticles":1144,"style":1157},708,"Related content",[1145,1146,1147,1148],{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631},{"id":435,"documentId":436,"createdAt":437,"updatedAt":438,"publishedAt":85,"locale":10,"title":439,"introduction":440,"content":441,"slug":442},{"id":713,"documentId":714,"createdAt":715,"updatedAt":716,"publishedAt":85,"locale":10,"title":717,"introduction":718,"content":719,"slug":720},{"id":1149,"documentId":1150,"createdAt":1151,"updatedAt":1152,"publishedAt":85,"locale":10,"title":1153,"introduction":1154,"content":1155,"slug":1156},607,"ok4077be735hxyo21hqag6f5","2026-03-24T12:54:45.593Z","2026-05-27T13:43:53.001Z","Now live: Create Tray Designs Directly from CAD Data in Your Browser","Planning plastic trays for transport, storage, or automated manufacturing processes often starts with one key question: what should a suitable tray for the component actually look like? This is exactly what the new web-based 3D Tray Generator answers within seconds. Learn more in this article.","\u003Ch2>Key Facts About the 3D Tray Generator at a Glance\u003C\u002Fh2>\u003Cul>\u003Cli>Tray concepts are automatically generated from 3D component data\u003C\u002Fli>\u003Cli>The tool runs directly in the browser without additional software installation\u003C\u002Fli>\u003Cli>Supports common CAD formats such as STL, STEP, OBJ, or GLTF\u003C\u002Fli>\u003Cli>Adjustments are displayed in real time in a 3D visualization\u003C\u002Fli>\u003Cli>Tray concepts can be submitted directly as an inquiry\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ The \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Ftray-generator\">Tray Generator\u003C\u002Fa> is now available free of charge with registration.\u003C\u002Fp>\u003Chr>\u003Ch2>Why Tray Concepts Are Often Created Too Late\u003C\u002Fh2>\u003Cp>In many projects, different departments need a tray concept early on, for example:\u003C\u002Fp>\u003Cul>\u003Cli>Logistics\u003C\u002Fli>\u003Cli>Production planning\u003C\u002Fli>\u003Cli>Work preparation\u003C\u002Fli>\u003Cli>Automation\u003C\u002Fli>\u003C\u002Ful>\u003Cp>However, tray design is often only created after an order is placed or as a paid engineering service. This leads to a typical gap in the project workflow:\u003C\u002Fp>\u003Cul>\u003Cli>Internal planning begins\u003C\u002Fli>\u003Cli>A suitable \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fsolutions\u002Ftrays-for-transportation-storage\">tray \u003C\u002Fa>does not yet exist\u003C\u002Fli>\u003Cli>Coordination loops arise between design and suppliers\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This process can take several days or even weeks. The web-based \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa> is designed to eliminate exactly this bottleneck.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1920\u002F1080;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_Generator_v2_Mockup_a422f20baf.webp\" alt=\"3D Tray Generator v2 Mockup\" width=\"1920\" height=\"1080\">\u003C\u002Ffigure>\u003Ch2>How the 3D Tray Generator Works\u003C\u002Fh2>\u003Cp>Using the tool is fully digital and only takes a few steps.\u003C\u002Fp>\u003Ch3>1. Upload CAD File\u003C\u002Fh3>\u003Cp>Users first upload the 3D file of their component. Supported formats include:\u003C\u002Fp>\u003Cul>\u003Cli>STEP \u002F STP\u003C\u002Fli>\u003Cli>STL\u003C\u002Fli>\u003Cli>OBJ\u003C\u002Fli>\u003Cli>GLB \u002F GLTF\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>2. Automatic Tray Generation\u003C\u002Fh3>\u003Cp>Based on the component geometry, the software automatically creates an initial tray concept. The following aspects are optimized automatically:\u003C\u002Fp>\u003Cul>\u003Cli>Component arrangement\u003C\u002Fli>\u003Cli>Nest spacing\u003C\u002Fli>\u003Cli>Packing density\u003C\u002Fli>\u003C\u002Ful>\u003Cp>This results in a realistic tray concept within seconds.\u003C\u002Fp>\u003Ch3>3. Customize Tray Concept\u003C\u002Fh3>\u003Cp>The generated tray can then be adjusted directly. In the interactive 3D view, users can configure:\u003C\u002Fp>\u003Cul>\u003Cli>Tray size\u003C\u002Fli>\u003Cli>Tray color\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">Material\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Material thickness\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fstacking-methods-for-trays\">Stacking method\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Grip recesses\u003C\u002Fli>\u003Cli>Poka-yoke corners\u003C\u002Fli>\u003C\u002Ful>\u003Cp>All changes are immediately visible in the 3D visualization.\u003C\u002Fp>\u003Ch2>New Features for Logistics and Production Planning\u003C\u002Fh2>\u003Cp>In addition to a new design, the latest version of the Tray Generator includes several features particularly relevant for logistics and production processes.\u003C\u002Fp>\u003Ch3>SLC Integration\u003C\u002Fh3>\u003Cp>The tool shows in real time how the generated tray fits into standardized SLC containers or outer cartons.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2109\u002F1755;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F3_D_Tray_im_KLT_Behaelter_Mockup_6fdbb638aa.webp\" alt=\"3D-Tray im KLT-Behälter Mockup\" width=\"2109\" height=\"1755\">\u003Cfigcaption>3D trays in their transport medium\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Custom Markings\u003C\u002Fh3>\u003Cp>Users can integrate symbols, labels, or logos directly into the tray to clearly identify components or variants.\u003C\u002Fp>\u003Ch3>Color Coding\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\u002Ftrays-with-color-stripes\">Color stripes\u003C\u002Fa> for variant identification can also be integrated directly into the tray design. This simplifies component identification in production processes.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2109\u002F1755;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGestapelte_3_D_Trays_mit_Farbstreifen_Mockup_ebe1f9ebe3.webp\" alt=\"Gestapelte 3D-Trays mit Farbstreifen\" width=\"2109\" height=\"1755\">\u003Cfigcaption>Stacked trays with color stripes\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>Stacking Methods and Stack Height\u003C\u002Fh3>\u003Cp>Different stacking methods can be defined, and maximum stack heights can be calculated. This allows early simulation of how trays behave in storage, transport, and production flow.\u003C\u002Fp>\u003Ch2>From Tray Concept Directly to Inquiry\u003C\u002Fh2>\u003Cp>Another feature of the tool is the direct processing of generated tray concepts.\u003C\u002Fp>\u003Cp>Users can:\u003C\u002Fp>\u003Cul>\u003Cli>Export their designs as a PDF\u003C\u002Fli>\u003Cli>Submit an inquiry directly\u003C\u002Fli>\u003C\u002Ful>\u003Cp>All relevant tray data is automatically transferred, eliminating much of the usual coordination effort.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1489\u002F1024;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FExportiertes_Tray_Konzept_als_PDF_f404c96409.webp\" alt=\"Exportiertes Tray-Konzept als PDF\" width=\"1489\" height=\"1024\">\u003C\u002Ffigure>\u003Ch2>Who Is the Tray Generator Especially Useful For?\u003C\u002Fh2>\u003Cp>The 3D Tray Generator is primarily aimed at companies that:\u003C\u002Fp>\u003Cul>\u003Cli>Develop new products\u003C\u002Fli>\u003Cli>Plan automated production lines\u003C\u002Fli>\u003Cli>Create transport concepts for components\u003C\u002Fli>\u003Cli>Need to define packaging concepts early in the project\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>Conclusion: Generate Tray Concepts Directly from CAD Data\u003C\u002Fh2>\u003Cp>With the web-based 3D Tray Generator, formary introduces a tool that solves a common bottleneck in industrial projects. Instead of developing tray concepts late in the process, users can now generate a tray layout within seconds, test variants, plan logistics concepts early, and submit inquiries directly.\u003C\u002Fp>\u003Cp>This makes plastic tray planning significantly faster, more transparent, and more efficient.\u003C\u002Fp>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Ftray-generator\">→ Create your tray concept now.\u003C\u002Fa>\u003C\u002Fp>","create-tray-designs-from-cad-data-in-your-browser",{"id":1158,"background":943,"border":85},3239,[1160],{"id":68,"documentId":598,"createdAt":1161,"updatedAt":1162,"publishedAt":85,"locale":128,"title":1163,"introduction":1164,"content":1165,"slug":1166},"2026-01-08T23:07:30.208Z","2026-06-02T16:56:22.200Z","Kunststoffteile konstruieren: 13 Designregeln für kunststoffgerechte Konstruktion im Thermoforming","Beim Konstruieren von Kunststoff Tiefziehteilen müssen bestimmte Designregeln beachtet werden, um Materialfehler, Verzug oder unnötige Kosten zu vermeiden. Faktoren wie Radien, Wandschrägen oder das Umformverhältnis haben direkten Einfluss auf die Bauteilqualität und Herstellbarkeit. In diesem Beitrag zeigen wir Ihnen die wichtigsten Konstruktionsregeln im Thermoforming. Praxisnah, verständlich und direkt umsetzbar.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Gestaltungsregeln bei der Konstruktion von Kunststoff Tiefziehteilen - Das Wichtigste in Kürze\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Radien & Wandschrägen:\u003C\u002Fstrong> Große Radien (mind. 1,5 mm) und Wandschrägen (>2°) erleichtern das Tiefziehen, verhindern Faltenbildung und Materialrisse.\u003C\u002Fli>\u003Cli>\u003Cstrong>Umformverhältnis & Wanddicke:\u003C\u002Fstrong> Das Verhältnis von Höhe zu Breite beeinflusst die Materialverstreckung; Ausgangsstärke und gewünschte Wanddicke müssen frühzeitig berechnet werden.\u003C\u002Fli>\u003Cli>\u003Cstrong>Tiefziehgerechte Geometrie:\u003C\u002Fstrong> Übergänge, Hinterschnitte, Toleranzen und Materialschrumpfung berücksichtigen, um Qualität, Entformbarkeit und Produktionskosten zu optimieren.\u003C\u002Fli>\u003C\u002Ful>\u003Cblockquote>\u003Cp>\u003Ci>→ Sie haben bereits CAD-Daten, die Sie auf Tiefziehbarkeit prüfen möchten? \u003C\u002Fi>Hier geht's zur \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">DfM-Analyse\u003C\u002Fa>\u003C\u002Fp>\u003Cp>→ Sie benötigen ein schnelles 3D Tray-Konzept? Hier geht's zum \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Ftray-generator\">3D Tray Generator\u003C\u002Fa>\u003C\u002Fp>\u003C\u002Fblockquote>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was sind die wichtigsten Gestaltungsregeln bei der Konstruktion von Tiefziehteilen?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Die wichtigsten Konstruktionsregeln für Kunststoff Tiefziehteile sind:\u003C\u002Fp>\u003Cul>\u003Cli>ausreichend große Radien zur Vermeidung von Rissen\u003C\u002Fli>\u003Cli>Wandschrägen für eine sichere Entformung\u003C\u002Fli>\u003Cli>ein passendes Umformverhältnis zur Kontrolle der Wanddicke\u003C\u002Fli>\u003Cli>reduzierte Hinterschnitte für eine einfache Fertigung\u003C\u002Fli>\u003Cli>materialgerechte Konstruktion zur Vermeidung von Verzug\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Werden diese Gestaltungsrichtlinien im Kunststoff Tiefziehen beachtet, lassen sich Qualität, Kosten und Prozesssicherheit deutlich verbessern. Mehr Details dazu finden Sie in den folgenden Abschnitten. \u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">1. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Radien\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FRadien_beim_Kunststoffteile_konstruieren_beachten_efb609b27b.png\" alt=\"Radien bei der Konstruktion von Kunststoffteilen\">\u003C\u002Ffigure>\u003Cp>Bei der Konstruktion von Kunststoffteilen ist es wichtig, immer möglichst großen Radien einzubauen, um das Streckverhalten zu begünstigen. Tiefziehteile sollte man immer mit einem Mindestradius von 1,5mm fertigen. \u003C\u002Fp>\u003Cp>Auf der Werkzeugseite ist man auf einen Mindestradius angewiesen, der als sehr grobe Faustregel (da abhängig von vielen Parametern) die Dicke der Ausgangsstärke des Materials nicht unterschreiten sollte.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Umgang mit scharfen Kanten\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Wenn scharfe Kanten nötig sind, dann setzen Sie bei der Konstruktion der Kunststoffteile mindestens einen Radius an, der so groß wie die Ausgangsstärke des Materials ist. Wird der Radius kleiner gesetzt, lassen sich die Daten entweder nicht, oder nur sehr umständlich tiefziehen. Außerdem erhöhen sich die Kosten durch längere Werkzeugfräszeiten.\u003Cbr> \u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FRadiusmoeglichkeiten_bei_Positiv_und_Negativwerzeugen_f9311cd2dd.png\" alt=\"Radiusmöglichkeiten bei Positiv- und Negativwerzeugen\">\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> \u003Cb>Achtung:\u003C\u002Fb> Am Tiefziehteil werden die Radien nochmals größer abgebildet als am Werkzeug selbst. Sowohl bei Positiv- als auch bei Negativwerkzeugen kommt es bei Vorgaben möglichst kleiner Radien vor allem darauf an, das Material so eng anliegend in die Ecken zu bekommen wie möglich. Der Radius an der werkzeugabgewandten Seite ergibt sich aus dem Radius der Werkzeugseite, sowie der Materialtype, der Materialverstreckung und der Materialdicke.      \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">2. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Wandschrägen\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Den Winkel zwischen der vertikalen Bauteilwand und der Entformrichtung bezeichnet man als Entformungsschräge. Da die Wahl der Entformungsschrägen die Geometrie des Tiefziehteils verändert, müssen die Winkel der Entformungsschrägen frühzeitig festgelegt und in die \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ffreigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten\">Konstruktionsdaten\u003C\u002Fa> eingearbeitet werden.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:30%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FKonstruktionstipps_fuer_Wandschraegen_am_Tiefziehteil_ad7720e7cc.png\" alt=\"Konstruktionstipps für Wandschrägen am Tiefziehteil\">\u003C\u002Ffigure>\u003Cp>Designen Sie die vertikalen Wände des Teils möglichst mit Wandschrägen, um eine einfache Entformung ohne optische Makel, wie Markierungen an der Oberfläche zu erreichen.\u003C\u002Fp>\u003Ch4>ℹ️ Empfohlene Wandschrägen generell: >2° \u003C\u002Fh4>\u003Cul>\u003Cli>Industriestandard für Negativwerkzeuge: 1,5 - 2°\u003C\u002Fli>\u003Cli>Industriestandard für Positivwerkzeuge: 4 - 6°\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">3. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Umformverhältnis und Wanddicke\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Das Umformverhältnis gibt die Relation zwischen Höhe und Breite\u003Cstrong> \u003C\u002Fstrong>der zu formenden Fläche wieder. Da das Material auf der begrenzten Fläche in die Tiefe verstreckt wird, dehnt sich dieses beim Umformen aus. Das Umformverhältnis ist hierbei abhängig von der Geometrie des \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ftiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugs\u003C\u002Fa> bzw. des resultierenden Tiefziehteils.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:29.52%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FUmformverhaetlnis_bei_der_Konstruktion_von_Tiefziehteilen_65263b290b.png\" alt=\"Umformverhätlnis bei der Konstruktion von Tiefziehteilen\">\u003C\u002Ffigure>\u003Cp>Die sich daraus resultierende Wanddicke lässt sich durch die folgende Formel überschlagen: \u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d2 = F1\u002FF2 * d1\u003C\u002Fstrong>\u003C\u002Fspan>\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>F1\u003C\u002Fstrong>\u003C\u002Fspan>\u003Cstrong>: \u003C\u002Fstrong>Fläche des Materialzuschnitts ohne Spannrand\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>F2: \u003C\u002Fstrong>\u003C\u002Fspan>Oberfläche des Tiefziehteils nach Formvorgang\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d1:\u003C\u002Fstrong>\u003C\u002Fspan>\u003Cstrong> \u003C\u002Fstrong>Materialausgangsstärke des Materials\u003C\u002Fli>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d2:\u003C\u002Fstrong>\u003C\u002Fspan>\u003Cstrong> \u003C\u002Fstrong>Resultierende Wandstärke (Ergebnis)\u003C\u002Fli>\u003C\u002Ful>\u003Cp>ℹ️ Mehr zu den Eck- und Kantenradien, Wandschrägen und Umformverhältnissen finden Sie unter \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Ftoleranzen\">Toleranzen\u003Cstrong>.\u003C\u002Fstrong>\u003C\u002Fa>\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">4. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Positiv- oder Negativformung und Wanddicke\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Je weiter bzw. tiefer das Material beim Thermoformen ins Werkzeug verstreckt wird, desto dünner wird die zurückbleibende Wandstärke. Üblicherweise wird die zu erzielende Wanddicke bestimmt, und dann zurückgerechnet (siehe Punkt 3), wie hoch die Ausgangsstärke des Materials sein muss (sogenanntes “reverse engineering.”)\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Streck- & Ziehverhältnis\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Das Streck- oder Ziehverhältnis beim Tiefziehen beschreibt das Längenverhältnis des Materials im Seitprofil (der Ausgangsstärke) und dem tiefgezogenen Tiefziehteil. Grundsätzlich gilt: Positiv geformte Teile führen bei gleicher Kontur zu einem kleineren und daher vorteilhafteren Streckverhältnis als negativ gezogene Teile.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPositiv_und_Negativformung_bei_Kunststoff_Tiefziehen_18c6967a04.png\" alt=\"Positiv- und Negativformung bei Kunststoff Tiefziehen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Wichtige Regeln beim Formvorgang\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Durch das viskoelastische Verhalten von Thermoplasten während der Verstreckung gilt es einige Faustregeln beim Formvorgang zu beachten, wenn Sie Kunststoffteile konstruieren:\u003C\u002Fp>\u003Cul>\u003Cli>Je kälter das Halbzeug bei der Verstreckung, desto größer die nötige Kraft, es zu verstrecken\u003C\u002Fli>\u003Cli>Je schneller die Verformungsgeschwindigkeit, desto größer die nötige Kraft, es zu verstrecken\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FPotenzielle_Schwachstellen_bei_der_Negativ_und_Positivformung_5ec414a3d3.png\" alt=\"Potenzielle Schwachstellen bei der Negativ- und Positivformung\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Positivformung\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bei negativ geformten Teilen liegt die Schwachstelle des Tiefziehteils nach Formung daher im Bodenbereich, da Material vom Rand in den Boden der Werkzeugkavität verstreckt wird. Dabei dünnt das Material aus.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Negativformung\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bei positiv geformten Teilen liegt die Schwachstelle des Tiefziehteils am Rand, da das Material zuerst am Bodenbereich des späteren Tiefziehteils auf das Positivwerkzeug aufsetzt, und den Randbereich nach unten ausdünnt. Zu dünn gewählte Ausgangsstärken und ein schlechtes Umformverhältnis, das heißt die Relation von Öffnungsbreite zu Öffnungstiefe, verschärfen den negativen Effekt zusätzlich.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tipp: \u003C\u002Fstrong>Wenn Sie unsicher sind, ob Ihr Bauteil tiefziehgerecht konstruiert ist, unterstützen wir Sie gerne bei der Auslegung und Optimierung Ihrer Konstruktion mit unserer \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">DfM-Analyse.\u003C\u002Fa> → Jetzt \u003Ca href=\"https:\u002F\u002Fmeetings.hubspot.com\u002Fmoritz-bittner-formary\u002Fdfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=76a35dfe-d3cd-4e65-8671-575c97d89d1c\">Demo\u003C\u002Fa> buchen. \u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">5. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Materialverstreckung bei Kavitäten\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Aufgrund der Materialverstreckung sollte bei der Konstruktion von Kunststoff Tiefziehteilen vor allem bei negativ gezogenen Nestern darauf geachtet werden, dass die Relation von Tiefe zu Breite der Kavität das Verhältnis 1,5 : 1 nicht überschreitet. Je tiefer die Tiefe T der Kavität in Relation zur Breite B, desto mehr dünnt das Material bei Verstreckung aus. Und je größer die Ausdünnung, desto höher die Chancen eines Aufrisses an der Bodenkante.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMaterialverstreckung_bei_der_Konstruktion_von_Tiefziehteilen_8ae1a4a0ac.png\" alt=\"Materialverstreckung bei der Konstruktion von Tiefziehteilen\">\u003C\u002Ffigure>\u003Cp>Die Tabelle erklärt die Möglichkeiten verschiedener Ziehverhältnisse bei negativen und positiven Formen:\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ziehverhältnis bei negativen und positiven Formen beim Konstruieren von Kunststoffteilen\u003C\u002Fspan>\u003C\u002Fh4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Ziehverhältnis (Tiefe zu Breite)\u003C\u002Fth>\u003Cth>positiv\u003C\u002Fth>\u003Cth>negativ\u003C\u002Fth>\u003C\u002Ftr>\u003C\u002Fthead>\u003Ctbody>\u003Ctr>\u003Ctd>0,3:1\u003C\u002Ftd>\u003Ctd>möglich\u003C\u002Ftd>\u003Ctd>möglich\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>0,5:1\u003C\u002Ftd>\u003Ctd>möglich\u003C\u002Ftd>\u003Ctd>+ Oberstempel\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>1:1\u003C\u002Ftd>\u003Ctd>möglich\u003C\u002Ftd>\u003Ctd>+ Oberstempel\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>1,5:1\u003C\u002Ftd>\u003Ctd>Materialverzug an der Grenze\u003C\u002Ftd>\u003Ctd>Materialverzug an der Grenze\u003C\u002Ftd>\u003C\u002Ftr>\u003Ctr>\u003Ctd>2:1\u003C\u002Ftd>\u003Ctd>Lässt sich nicht simulieren. Muss getestet werden.\u003C\u002Ftd>\u003Ctd>Lässt sich nicht simulieren. Muss getestet werden.\u003C\u002Ftd>\u003C\u002Ftr>\u003C\u002Ftbody>\u003C\u002Ftable>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">6. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Übergangskonturen\u003C\u002Fspan>\u003Cspan style=\"color:#005250;\"> \u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Wie schon angemerkt: Beim Thermoforming gilt es in der Konstruktion mit Kunststoffen, kleine Radien zu umgehen. Gerade bei passformgenauen Bauteilkavitäten lassen sich Nester unter Einhaltung der vollen Funktionalität in abgeschwächten Konturen deutlich besser tiefziehbar gestalten.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Verbesserte Formbarkeit durch entschärfte Konturen\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>In Abbildung 1 ist eine schlecht tiefziehbare Kavitätenkontur dargestellt, in Abbildung 2 eine entschärfte Kontur, welche sich gut formen lässt. Durch die Entschärfung der Entformungsschrägen und Radien lässt sich das Tiefziehteil besser ziehen, was die Qualität erhöht. Außerdem wird das Risiko von Aufrissen dadurch minimiert, sowie höhere Reproduzierbarkeiten garantiert.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FUebergangskonturen_als_wichtige_Gestaltungsregel_fuer_Kunststoff_Tiefziehteile_23791459cd.png\" alt=\"Übergangskonturen als wichtige Gestaltungsregel für Kunststoff Tiefziehteile\">\u003C\u002Ffigure>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FAbgemilderte_Hoehenuebergange_bei_der_Konstruktion_von_Kunststoffteilen_3c4e2785f7.png\" alt=\"Abgemilderte Höhenübergange bei der Konstruktion von Kunststoffteilen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Vorteile für Produktion und Kosten\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Schlussendlich sind auch die Taktzeiten kürzer, was in einem allgemein erfreulichen, günstigeren Stückpreis mündet. Auch Übergänge von Randkonturen oder Stufenbereichen können durch Schrägen entschärft werden.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Risiken bei kleinen Radien und mögliche Lösungen\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bei zu kleinen Radien besteht gerade beim positiven Formen immer die Gefahr der Faltenbildung beim Tiefziehen. Um Falten zu umgehen, können auch bei der Kunststoff Konstruktion rippenförmige Übergänge angesetzt werden, um eine Falte beim Positiv-Tiefziehen zumindest gezielt zu formen.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FFalten_gezielt_bei_der_Konstrukion_von_Kunststoff_Tiefziehteilen_einsetzen_466f8d330d.png\" alt=\"Faltenbildung gezielt konstruieren bei Kunststoffteilen\">\u003Cfigcaption>Faltenbildung durch angedeutete Rippen\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">7. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Hinterschnitte\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Hinterschnitte sind Geometrien, die das Teil am einfachen Herauslösen aus dem Tiefziehwerkzeug hindern. Anders als beim Spritzguss gibt es keine zweite Werkzeughälfte, daher erschweren sie die Entformung.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tipps:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Hinterschnitte möglichst vermeiden oder auf ein tiefziehbares Niveau reduzieren.\u003C\u002Fli>\u003Cli>Bei Stapel-Elementen oder Klemmungen sind Hinterschnitte oft unvermeidbarl, daher ist eine sorgfältige Konstruktion erforderlich.\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n\u003Ch4>ℹ️ Ist Ihr Bauteil tiefziehgerecht?\u003C\u002Fh4>      \n\u003Cp> Viele Konstruktionsfehler entstehen bereits im CAD-Modell und führen später zu höheren Kosten oder Qualitätsproblemen. Wir prüfen Ihre Konstruktion und geben Ihnen konkrete Optimierungsvorschläge für eine wirtschaftliche und fertigungssichere Umsetzung.    \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">8. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Verarbeitungsschwindung\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Denken Sie daran, dass die Verarbeitungsschwindung beim Design eines Kunststoff Tiefziehteils ein wichtiger Faktor ist, der die Endgröße und Form beeinflusst. Nach der Entformung schrumpft das Teil aufgrund des Materialverhaltens noch weiter. Diese Schwindung variiert je nach Material und kann auch nach dem Abkühlen des Teils noch bis zu 24 Stunden anhalten. Insbesondere bei teilkristallinen Thermoplasten hört die Nachschwindung nie auf und das Teil kann sich mit der Zeit weiter verkleinern.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Gegenmaßnahmen bei Verarbeitungsschwindung\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Werkzeuggröße unter Berücksichtigung der Schwindung planen.\u003C\u002Fli>\u003Cli>Musterprüfung vor Produktionsstart durchführen.\u003C\u002Fli>\u003Cli>\u003Cstrong>Faktoren:\u003C\u002Fstrong> Materialwahl, Entformtemperatur, Extrusion und interne Spannungen.\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">9. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Tiefziehfähige Toleranzen\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Tiefziehteile werden für einen Großteil der industriellen und Verpackungs-Anwendungen mit einer Toleranz von +\u002F- ~1 mm konstruiert. Das entspricht dem Toleranzfeld nach ISO 2768-c für das in diesem Produktbereich gängige 120 bis 400mm Längenmaß.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehfaehige_Toleranzen_beim_Konstruieren_von_Kunststoff_Tiefziehteilen_bec9b8d967.png\" alt=\"Tiefziehfähige Toleranzen beim Konstruieren von Kunststoff Tiefziehteilen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Zusätzliche Kosten bei engen Toleranzen\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Das Formen von engeren Toleranzen ist meistens mit zusätzlichen Kosten verbunden. Diese sind auf längere Entformzeiten, größere Fertigungsaufwände und\u002Foder längere Taktzeiten zurückzuführen.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ Wichtig ist, dass Toleranzen nicht unnötig eng gewählt werden: Das Motto \u003Cb>„So groß wie möglich, so klein wie nötig“\u003C\u002Fb> gilt als allgemeine Richtlinie in der Konstruktionsanleitung.     \n\u003C\u002Fp>\n    \u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">10. Gestaltungsregel bei Kunststoff Tiefziehteilen bei Baugruppen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Befestigungspunkte\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Um verschiedene Tiefziehteile oder Baugruppen zusammenzusetzen, sind Befestigungspunkte nötig. Beim sicheren Verschluss von Tiefziehteilen kommen viele Optionen der Verbindungstechnik zum Einsatz. Diese müssen von Anfang an für das kunststoffgerechte Konstruieren wohl überlegt werden.\u003C\u002Fp>\u003Cp>Abhängig von der mechanischen Belastung, der Häufigkeit des Öffnens und Verschließens und der Verbindungsstabilität, stehen verschiedene Möglichkeiten zur Erreichung eines Kraftschlusses zur Verfügung.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FBefestigungspunkte_anbringen_bei_der_Konstruktion_von_Kunststoffteilen_63583aa096.png\" alt=\"Befestigungspunkte anbringen bei der Konstruktion von Kunststoffteilen\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Schrauben oder Nieten für kraftschlüssige Verbindungen\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Bei permanent kraftschlüssigen Verbindungen werden an den Übergangsstellen zwischen zwei Teilen häufig Schrauben oder Nieten an die Tiefziehteile angebracht, um eine Verbindung zu erzielen.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">11. Gestaltungsregel bei Kunststoff Tiefziehteilen bei Stapelung: Stapeltechnik\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Wenn Ihr Tiefziehteil gestapelt werden soll, muss das schon frühzeitig im Tiefziehteil Design beachtet werden, sodass für die Stapelung Platz gelassen wird. Bei der Selektion der passenden \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ftransportschaeden-vermeiden-mithilfe-dieser-4-stapeltechniken\">Stapeltechnik\u003C\u002Fa> entscheiden verschiedene Punkte:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Materialausgangsstärke\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Die Wahl der Stapelung eines Tiefziehteils hängt in erster Linie von der Steifigkeit des Tiefziehteils und den Gleiteigenschaften des Materials ab. Je dicker das Material (oft bei Mehrwegtrays der Fall), desto besser lässt sich stapeln. Je schlechter die Gleiteigenschaften des Materials, desto besser die Haftreibung, und desto besser lässt sich dadurch stapeln.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensibilität der Produkte\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Wenn nicht über die Bauteile gestapelt werden darf (oder soll), sondern einige mm Luft eingehalten werden, wird eine hochwertigere Stapeltechnik benötigt. Der Grund ist, dass die Stapelung des Tiefziehteils selbsttragend ist, d.h. das Gewicht der Trays und des Inhalts ohne zusätzliche Abstützungen auf der Trayfläche tragen muss.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Dringlichkeit des Zeitplans\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Komplexe Stapeltechniken mit beweglichen Stapelelementen setzen die Fertigung aus einem Klappenwerkzeug voraus. Die Herstellung eines solchen Werkzeugs ist zeitintensiver als ein relativ einfach gehaltenes Hinterschnittstapelungs-Werkzeug.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">12. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Materialauswahl\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Weichere Kunststoffe haben nach der Entformung \u003Cstrong>größere Rückverformungen\u003C\u002Fstrong> und höhere Verarbeitungsschwindungen. \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fmaterialien\">Materialien\u003C\u002Fa> mit hoher Härte und Steifigkeit sind automatisch in einer besseren Toleranzgruppe in puncto Genauigkeit.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> ℹ️ Mehr zu Kunststoffen, ihren Eigenschaften und deren Einfluss auf die Gesamtkosten im Tiefziehen, können Sie in unserem Whitepaper \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fwhitepaper-ebooks\u002Fmaterialleitfaden-fuer-kunststoff-tiefziehteile\">Materialleitfaden für Kunststoff Tiefziehteile\u003C\u002Fa> nachlesen. \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">13. Zusatztipp: \u003C\u002Fspan>\u003Cspan style=\"color:#00a9a5;\">Optimal gesetzte Gravuren\u003C\u002Fspan>\u003C\u002Fh2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:36.72%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGravuren_bei_Kunstsoff_Tiefziehteilen_9998ef3f99.png\" alt=\"Gravuren bei Kunstsoff Tiefziehteilen\">\u003C\u002Ffigure>\u003Cp>Sollten Sie Kennzeichnungen im Tiefziehteil benötigen, können Sie diese gerne direkt mit einer Gravur in das Werkzeug einbringen.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Kosten der Gravur\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Die Kosten der Gravur können sehr unterschiedlich ausfallen, je nachdem, wie diese eingebracht werden muss. Als Faustregel gilt: Eine negativ (versenkt) eingebrachte Gravur ist relativ kostengünstig, eine positiv eingebrachte (erhabene) Gravur deutlich aufwendiger, und daher teurer.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Kunststoffteile konstruieren: Mit den richtigen Regeln zum optimalen Ergebnis\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Durch das Beachten dieser Design-Grundregeln können potenzielle Fehlerquellen bereits in der Konstruktionsphase vermieden werden. Das trägt zur \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fleitfaden-zur-kostenreduktion-im-tiefziehen\">Kostenreduktion\u003C\u002Fa> bei, verringert Iterationsschleifen und sorgt für eine sichere Produktion.\u003C\u002Fp>\u003Cp>Sie möchten sicherstellen, dass Ihr Bauteil optimal für das Tiefziehen ausgelegt ist? Wir unterstützen Sie gerne bei der konstruktionstechnischen Auslegung und Umsetzung Ihrer Tiefziehteile und empfehlen für mehr Verständnis unseren \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fdesign-guide\">Design-Guide.\u003C\u002Fa>\u003C\u002Fp>","gestaltungsregeln-bei-kunststoff-tiefziehteilen",{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631,"cover":1168,"seo":1218,"blog_author":1232,"blogcategory":1240,"inline_hubspot_form":85,"blocks":1284,"localizations":1323},{"id":1169,"documentId":1170,"name":1171,"alternativeText":628,"caption":16,"width":363,"height":213,"formats":1172,"hash":1213,"ext":304,"mime":307,"size":1214,"url":1215,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1216,"updatedAt":1216,"publishedAt":1217},2078,"dkdy1x18tz5dlnvewc8dwpq0","Construction Data in Thermoforming: These Factors Must Be Considered for Plastic Deep Drawn Parts Banner 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more.",{"id":1169,"documentId":1170,"name":1171,"alternativeText":628,"caption":16,"width":363,"height":213,"formats":1223,"hash":1213,"ext":304,"mime":307,"size":1214,"url":1215,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1216,"updatedAt":1216,"publishedAt":1217},{"lg":1224,"md":1225,"sm":1226,"xl":1227,"2xl":1228,"avatar":1229,"default":1230,"thumbnail":1231},{"ext":304,"url":1174,"hash":1175,"mime":307,"name":1176,"path":85,"size":1177,"width":165,"height":220},{"ext":304,"url":1179,"hash":1180,"mime":307,"name":1181,"path":85,"size":1182,"width":157,"height":375},{"ext":304,"url":1184,"hash":1185,"mime":307,"name":1186,"path":85,"size":1187,"width":173,"height":381},{"ext":304,"url":1189,"hash":1190,"mime":307,"name":1191,"path":85,"size":1192,"width":147,"height":387},{"ext":304,"url":1194,"hash":1195,"mime":307,"name":1196,"path":85,"size":1197,"width":212,"height":393},{"ext":304,"url":1199,"hash":1200,"mime":307,"name":1201,"path":85,"size":1202,"width":310,"height":399},{"ext":304,"url":1204,"hash":1205,"mime":307,"name":1206,"path":85,"size":1207,"width":233,"height":34},{"ext":304,"url":1209,"hash":1210,"mime":307,"name":1211,"path":85,"size":1212,"width":410,"height":411},{"id":509,"documentId":510,"createdAt":511,"updatedAt":512,"publishedAt":85,"locale":10,"role":513,"name":514,"email":515,"phone":516,"meeting_url":517,"image":1233,"localizations":1238},{"id":519,"documentId":520,"name":521,"alternativeText":522,"caption":16,"width":173,"height":523,"formats":1234,"hash":541,"ext":304,"mime":307,"size":542,"url":543,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":544,"updatedAt":544,"publishedAt":545},{"avatar":1235,"default":1236,"thumbnail":1237},{"ext":304,"url":526,"hash":527,"mime":307,"name":528,"path":85,"size":529,"width":310,"height":310},{"ext":304,"url":531,"hash":532,"mime":307,"name":533,"path":85,"size":534,"width":233,"height":535},{"ext":304,"url":537,"hash":538,"mime":307,"name":539,"path":85,"size":540,"width":182,"height":182},[1239],{"id":548,"documentId":510,"createdAt":549,"updatedAt":549,"publishedAt":85,"locale":128,"role":550,"name":514,"email":515,"phone":516,"meeting_url":517},{"id":552,"documentId":553,"createdAt":554,"updatedAt":555,"publishedAt":85,"locale":10,"title":556,"slug":557,"description":558,"blogarticles":1241,"seo":1281,"localizations":1282},[1242,1243,1244,1245,1246,1247,1248,1249,1250,1251,1252,1253,1254,1255,1256,1257,1258,1259,1260,1261,1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275,1276,1277,1278,1279,1280],{"id":561,"documentId":562,"createdAt":563,"updatedAt":564,"publishedAt":85,"locale":10,"title":565,"introduction":566,"content":567,"slug":568},{"id":570,"documentId":571,"createdAt":572,"updatedAt":573,"publishedAt":85,"locale":10,"title":574,"introduction":575,"content":576,"slug":577},{"id":579,"documentId":580,"createdAt":581,"updatedAt":582,"publishedAt":85,"locale":10,"title":583,"introduction":584,"content":585,"slug":586},{"id":588,"documentId":589,"createdAt":590,"updatedAt":591,"publishedAt":85,"locale":10,"title":592,"introduction":593,"content":594,"slug":595},{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},{"id":606,"documentId":607,"createdAt":608,"updatedAt":609,"publishedAt":85,"locale":10,"title":610,"introduction":611,"content":612,"slug":613},{"id":615,"documentId":616,"createdAt":617,"updatedAt":618,"publishedAt":85,"locale":10,"title":619,"introduction":620,"content":621,"slug":622},{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631},{"id":633,"documentId":634,"createdAt":635,"updatedAt":636,"publishedAt":85,"locale":10,"title":637,"introduction":638,"content":639,"slug":640},{"id":642,"documentId":643,"createdAt":644,"updatedAt":645,"publishedAt":85,"locale":10,"title":646,"introduction":647,"content":648,"slug":649},{"id":651,"documentId":652,"createdAt":653,"updatedAt":654,"publishedAt":85,"locale":10,"title":655,"introduction":656,"content":657,"slug":658},{"id":660,"documentId":661,"createdAt":662,"updatedAt":663,"publishedAt":85,"locale":10,"title":664,"introduction":665,"content":666,"slug":667},{"id":669,"documentId":670,"createdAt":671,"updatedAt":672,"publishedAt":85,"locale":10,"title":673,"introduction":674,"content":675,"slug":676},{"id":678,"documentId":679,"createdAt":680,"updatedAt":681,"publishedAt":85,"locale":10,"title":682,"introduction":683,"content":684,"slug":685},{"id":687,"documentId":688,"createdAt":689,"updatedAt":690,"publishedAt":85,"locale":10,"title":691,"introduction":692,"content":693,"slug":694},{"id":696,"documentId":697,"createdAt":698,"updatedAt":699,"publishedAt":85,"locale":10,"title":700,"introduction":701,"content":702,"slug":703},{"id":381,"documentId":705,"createdAt":706,"updatedAt":707,"publishedAt":85,"locale":10,"title":708,"intro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Asked Questions about Design Data in Thermoforming",[1289,1293,1297,1301,1305,1309],{"id":1290,"title":1291,"content":1292},10229,"What is design data in thermoforming?","\u003Cp>Design data refers to the CAD files or derived dimensioned drawings of the thermoformed part. It contains all information needed for manufacturing, sampling, and series production, such as dimensions, material, radii, draft angles, cavity geometries, and installation situations.\u003C\u002Fp>\n",{"id":1294,"title":1295,"content":1296},10230,"What formats are used for design data?","\u003Cul>\n\u003Cli>\n\u003Cstrong>3D data:\u003C\u002Fstrong> STEP format for platform-independent exchange of 3D models\n\u003C\u002Fli>\n\u003Cli>\n\u003Cstrong>2D drawings:\u003C\u002Fstrong> PDF with all dimensions, tolerances, material specifications, and textures\n\u003C\u002Fli>\n\u003C\u002Ful>",{"id":1298,"title":1299,"content":1300},10231,"Why is initial material thickness important?","\u003Cp>Initial material thickness describes the thickness of the plastic sheet or roll used in thermoforming. It influences the stability, geometry, and formability of the part. Different initial thicknesses can be sampled to achieve the optimal result.\u003C\u002Fp>",{"id":1302,"title":1303,"content":1304},10232,"What factors must be checked when approving design data?","\u003Cul>\n\u003Cli>\n\u003Cstrong>Dimensions:\u003C\u002Fstrong> Length, width, height, and tolerances according to DIN ISO 2768\n\u003C\u002Fli>\n\u003Cli>\n\u003Cstrong>Cavity geometry:\u003C\u002Fstrong> Optimal orientation for transport, assembly, and storage\n\u003C\u002Fli>\n\u003Cli>\n\u003Cstrong>Installation situation:\u003C\u002Fstrong> Accurate fit of the part in the overall assembly\n\u003C\u002Fli>\n\u003Cli>\n\u003Cstrong>Material & properties:\u003C\u002Fstrong> Temperature resistance, hardness, UV and ESD protection, chemical resistance\n\u003C\u002Fli>\n\u003C\u002Ful>",{"id":1306,"title":1307,"content":1308},10233,"What is meant by cavity geometry?","\u003Cp>Cavity geometry defines how components are placed in trays or containers. It is important for safe transport, easy removal, and optimal packing density.\u003C\u002Fp>\n",{"id":1310,"title":1311,"content":1312},10234,"What is the advantage of customer review of design data?","\u003Cp>The review makes it possible to identify and adjust missing or overlooked requirements at an early stage, making sampling and series production more efficient and error-free.\u003C\u002Fp>",{"__component":430,"id":1314,"title":1315,"variant":289,"cta_button":85,"blogarticles":1316,"style":1321},830,"Further Content",[1317,1318,1319,1320],{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},{"id":435,"documentId":436,"createdAt":437,"updatedAt":438,"publishedAt":85,"locale":10,"title":439,"introduction":440,"content":441,"slug":442},{"id":713,"documentId":714,"createdAt":715,"updatedAt":716,"publishedAt":85,"locale":10,"title":717,"introduction":718,"content":719,"slug":720},{"id":839,"documentId":840,"createdAt":841,"updatedAt":842,"publishedAt":85,"locale":10,"title":843,"introduction":844,"content":845,"slug":846},{"id":1322,"background":943,"border":85},3380,[1324],{"id":1325,"documentId":625,"createdAt":1326,"updatedAt":1327,"publishedAt":85,"locale":128,"title":1328,"introduction":1329,"content":1330,"slug":1331},258,"2026-01-08T23:07:24.042Z","2026-05-26T11:37:14.058Z","Konstruktionsdaten im Thermoforming: Diese Faktoren sind zu beachten","Tiefziehteile sind kundenspezifisch und werden individuell in einem CAD-Format konstruiert. Bevor ein Tiefziehwerkzeug gefertigt wird, erfolgt ein kundenseitiger Freigabeprozess der CAD Daten, bzw. der daraus abgeleiteten, bemaßten PDF Zeichnung. Dieser Beitrag erläutert den Erstellungs- und Freigabeprozess der Konstruktionsdaten eines Kunststoff Tiefziehteils und hebt die wichtigsten Faktoren hervor, die auf Kundenseite bei der Freigabe wichtig sind.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Konstruktiondaten im Thermoforming - Das Wichtigste in Kürze\u003C\u002Fspan>\u003C\u002Fh2>\u003Cul>\u003Cli>\u003Cstrong>Präzision der Konstruktionsdaten:\u003C\u002Fstrong> Maße, Material, Materialstärke, Wandschrägen und Radien müssen genau geprüft werden, um Funktionalität, Qualität und Design des Tiefziehteils sicherzustellen.\u003C\u002Fli>\u003Cli>\u003Cstrong>Nestergeometrie & Verbausituation:\u003C\u002Fstrong> Bauteile müssen für Transport, Montage und Integration ins Gesamtprodukt optimal gestaltet sein. Die Toleranzen und Packdichte sind entscheidend.\u003C\u002Fli>\u003Cli>\u003Cstrong>Prozess & Datenformate:\u003C\u002Fstrong> CAD-Daten (STEP für 3D, PDF für 2D) werden erstellt, geprüft, freigegeben und bemustert, bevor die Serienproduktion startet (Zeitrahmen ca. 3–5 Wochen).\u003C\u002Fli>\u003C\u002Ful>\u003Cp>→ Sie haben bereits eine CAD-Datei, die Sie auf Tiefziehbarkeit prüfen wollen? Laden Sie diese in unserer automatisierten \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">DfM-Analyse\u003C\u002Fa> hoch und erhalten innerhalb weniger Sekunden eine Machbarkeitsprüfung.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was sind Konstruktionsdaten?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Wenn im \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Ftiefziehen-kunststoff\">Kunststoff Tiefziehen\u003C\u002Fa> von Konstruktionsdaten gesprochen wird, ist die CAD \u003Cstrong>(Computer-Aided-Design)\u003C\u002Fstrong>-Datei oder die davon abgeleitete, bemaßte Zeichnung (oft im PDF Format) des fertigen Endprodukts, hier also das Tiefziehteil, gemeint.\u003C\u002Fp>\u003Cp>Bei der Erstellung der Daten fließen sowohl Kundenanforderungen als auch Design for Manufacturing (DfM) Empfehlungen auf Tiefzieher- oder Werkzeugbauer-Seite ein.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typische Parameter im Thermoforming\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Längenmaße\u003C\u002Fli>\u003Cli>Nestergeometrien\u003C\u002Fli>\u003Cli>Materialstärken\u003C\u002Fli>\u003Cli>Verbausituationen\u003C\u002Fli>\u003Cli>Aussparungen für spätere Bearbeitung\u003C\u002Fli>\u003Cli>Radien und Wandschrägen für Tiefziehbarkeit\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Die \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fgestaltungsregeln-bei-kunststoff-tiefziehteilen\">Konstruktion des Kunststoff Tiefziehteils\u003C\u002Fa> dient als Grundlage für die Erstellung des \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ftiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugs\u003C\u002Fa> aus Aluminium. Wenn das Werkzeug erstellt ist, erfolgt im nächsten Schritt die Musterfreigabe.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Kundenanforderungen bei Konstruktionsdaten\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Meist entwickelt formary auf Basis der Kundenanforderungen das Produkt und ergo die Konstruktionsdaten komplett auf der grünen Wiese. Manchmal stellen Kunden jedoch auch bereits fertige CAD Daten des Tiefziehteils zur Verfügung. Dies geschieht entweder, wenn das Kunststoff Tiefziehteil schon im Unternehmen existiert und neu angefragt wird oder die interne Konstruktionsabteilung einen Vorschlag erstellt hat.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Prozess bei bestehenden CAD-Daten\u003C\u002Fspan>\u003C\u002Fh3>\u003Col>\u003Cli>Prüfung auf \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fdesign-for-manufacturing\">Design for Manufacturability (DfM)\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Anpassung auf Tiefziehbarkeit\u003C\u002Fli>\u003Cli>Kundenprüfung auf Vollständigkeit und Richtigkeit\u003C\u002Fli>\u003C\u002Fol>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1456\u002F784;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FMaterialzusammensetzung_im_Konfigurator_5bb4cce829.png\" alt=\"Materialzusammensetzung im Konfigurator\" width=\"1456\" height=\"784\">\u003Cfigcaption>Ausschnitt aus dem formary Konfigurator\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Welches Format sollten Ihre Konstruktionsdaten haben?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Die Konstruktionsdaten werden Kunden bei formary immer in Form von 2D-Zeichnungen im PDF-Format und 3D-Daten im STEP-Format zur Verfügung gestellt.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Was bedeutet STEP?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>STEP (\u003Cstrong>St\u003C\u002Fstrong>andard for the \u003Cstrong>E\u003C\u002Fstrong>xchange of \u003Cstrong>P\u003C\u002Fstrong>roduct model data) ist ein Dateityp, das den Austausch von 3D-Modellen zwischen CAD-Systemen, unabhängig davon, auf welchem System das Modell erstellt wurde, ermöglicht.\u003C\u002Fp>\u003Cp>Die technische Zeichnung enthält detaillierte Informationen über:\u003C\u002Fp>\u003Cul>\u003Cli>Texturen\u003C\u002Fli>\u003Cli>Toleranzen\u003C\u002Fli>\u003Cli>Materialeigenschaften\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Die präzise und sorgfältige Prüfung der Konstruktionsdaten ist relevant, um sicherzustellen, dass die thermogeformten Teile den gewünschten Anforderungen bezüglich Funktionalität, Qualität und Design entsprechen.\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">Die wichtigsten Faktoren bei der Prüfung von Konstruktionsdaten zur Freigabe\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Um sicherzustellen, dass die erstellte Tiefzieh-Konstruktion den Anforderungen entspricht und die Funktionalität gewährleistet ist, müssen folgende Faktoren sorgfältig berücksichtigt werden:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">Maße\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Die toleranzgenaue Einhaltung der Längenmaße (z.B. Länge x Breite x Höhe) ist immer relevant, um sicherzustellen, dass das Endprodukt die gewünschten Spezifikationen erfüllt. Dabei sollte geprüft werden, ob die Konstruktionsdaten maßhaltig nach der besprochenen DIN ISO 2768 Längenmaßnorm erstellt wurden.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefzieh_Abdeckung_Abmessungen_26cbd7985c_1_46c01ef13b.jpg\" alt=\"Abmaße des Tiefzieh-Werkzeugs\">\u003Cfigcaption>Bauteilmaße Länge x Breite x Höhe\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Nestergeometrie\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Die \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fso-bestimmen-sie-die-geeigneten-formnester-ihres-werkstuecktraegers-1\">Nestergeometrie \u003C\u002Fa>ist insbesondere bei \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Floesungen\u002Fkunststofftray-lagerung-transport\">Kunststofftrays \u003C\u002Fa>ausschlaggebend. Konstruktionsdaten sollten klar dokumentieren:\u003C\u002Fp>\u003Cul>\u003Cli>Werden die Bauteile in besprochener Ausrichtung eingelegt?\u003C\u002Fli>\u003Cli>Werden die Bauteile an der gewünschten Geometrie aufgenommen, um sicher auf dem geplanten Transportweg (Werk, Straße oder Schiene) befördert zu werden?\u003C\u002Fli>\u003Cli>Sind Griffmulden zur Entnahme gewünscht und vorhanden?\u003C\u002Fli>\u003Cli>Ist die Packdichte wie besprochen?\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Die Konstruktionsdaten sollten demnach klare Angaben zu den Randbedingungen und Toleranzen enthalten, die für die Nestergeometrie der Kunststoff Tiefziehteile gelten. Dies bedeutet, dass die Teile so konstruiert werden sollten, dass sie den verfügbaren Raum optimal ausnutzen und gleichzeitig einen reibungslosen Produktionsablauf ermöglichen.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsm_0068_bit_003_formary_50028_transport_5a6906c90d_1_41d10960f4.jpg\" alt=\"Nestergeometrie des Tiefziehteils\">\u003Cfigcaption>Tiefziehtray mit formangepassten Nestern\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ \u003Cb>Tipp:\u003C\u002Fb> Laden Sie Ihre Bauteildaten in unserem \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Ftray-generator\">3D Tray Generator.\u003C\u002Fa> hoch und erhalten in wenigen Sekunden ein 3D-Tray-Design mit passender Nestergeometrie.\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch3>\u003Cspan style=\"color:#005250;\">Verbausituation\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Floesungen\u002Fkunststoff-abdeckungen-gehaeuse\">Abdeckungen\u003C\u002Fa> erfordern konkrete Daten zur Verbausituation. Die Verbausituation bezieht sich auf die Integration des thermoformten Teils in das Gesamtprodukt oder die Gesamtbaugruppe des Kundenprodukts. Diese ist wichtig, um sicherzustellen, dass das Teil problemlos in die vorgesehene Umgebung passt und alle Montageanforderungen erfüllt. Daher ist zu prüfen:\u003C\u002Fp>\u003Cul>\u003Cli>Stimmen die Maße an Befestigungs- und Anbaupunkten mit den Spezifikationen überein?\u003C\u002Fli>\u003Cli>Sind Toleranzen für die Montage berücksichtigt?\u003C\u002Fli>\u003Cli>Ist die Kompatibilität mit anderen Komponenten gesichert?\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsm_0024_bit_003_formary_50200_abdeckung_084035d392_1_92852eb019.jpg\" alt=\"Verbausituation der Tiefziehteile\">\u003Cfigcaption>Tiefgezogene Kunststoffabdeckungen\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Verschiedene Kunststoffe haben unterschiedliche Eigenschaften und eignen sich für unterschiedliche Anwendungen. Das auf der Zeichnung spezifizierte Material sollte demnach auf Korrektheit geprüft werden.\u003C\u002Fp>\u003Ch4>\u003Cspan style=\"color:#005250;\">Wichtige Materialeigenschaften\u003C\u002Fspan>\u003C\u002Fh4>\u003Cul>\u003Cli>Temperaturbeständigkeit\u003C\u002Fli>\u003Cli>Härte\u003C\u002Fli>\u003Cli>UV-Schutz\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fesd-trays-aus-kunststoff-einsatz-und-vorteile\">ESD-Schutz\u003C\u002Fa>\u003C\u002Fli>\u003Cli>Chemische Beständigkeit\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Mehr Informationen zu Kunststoffen finden Sie in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fmaterialien\">Materialien\u003C\u002Fa>.\u003C\u002Fp>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fmd_kunststoff_granulat_9b0e2d4096_1_267ca762c0.jfif\" alt=\"Material und Materialausgangsstärke\">\u003Cfigcaption>Kunststoffgranulat\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Materialausgangsstärke\u003C\u002Fspan>\u003C\u002Fh4>\u003Cp>Die Materialausgangsstärke bezieht sich auf die Dicke der \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fplattenfertigung\">Kunststoffplatte \u003C\u002Fa>oder \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Frollenfertigung\">-rolle,\u003C\u002Fa> welche beim Thermoforming verwendet wird. Die Materialausgangsstärke wurde während der Erstellung des Angebots auf Basis technischer Kriterien festgelegt und kann daher mit diesem abgeglichen werden.\u003C\u002Fp>\u003Cp>Werden mehrere Ausgangsstärken bemustert, um das optimale Stabilitäts- und Geometrieergebnis zu erzielen, wird die finale Konstruktionszeichnung entsprechend auf die gewählte Lösung aktualisiert.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp>ℹ️ Welche Gestaltungsregeln es bei der Konstruktion von Tiefziehteilen zu beachten gilt, lesen Sie im Beitrag  \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fgestaltungsregeln-bei-kunststoff-tiefziehteilen\">Gestaltungsregeln bei Kunststoff Tiefziehteilen.\u003C\u002Fa>\u003C\u002Fp>\n    \u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">Der Prozessablauf zur Erstellung und Überprüfung der Konstruktionsdaten bei formary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Für die Erstellung und Überprüfung von Konstruktionsdaten sieht der Prozess folgendermaßen aus: \u003Cstrong>Anforderungen - Konstruktion - Datenfreigabe - Muster - Musterfreigabe - Serie.\u003C\u002Fstrong>\u003C\u002Fp>\u003Cp>Im Detail verläuft die \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fprojektplanung-im-thermoforming\">Projektplanung im Thermoforming\u003C\u002Fa> grob unterteilt in folgenden Schritten:\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Fragen Sie Ihr Projekt an\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Tragen Sie ihre Anforderungen im Konfigurator ein und schicken formary Ihre Anfrage ab. Innerhalb von 24 Stunden erhalten Sie ein Angebot.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefziehteil_anfragen_Laptop_Mockup_2b60f6315d.png\" alt=\"Projektanfrage\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Lassen Sie uns Ihre Daten erstellen\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Im zweiten Schritt stehen Ihnen zwei Optionen zur Verfügung:\u003C\u002Fp>\u003Cul>\u003Cli>Sie haben eine Konstruktionsabteilung?\u003Cul>\u003Cli>Dann erstellen Sie gerne selbst Ihr Kunststoff Tiefziehteil. Gerne können Sie unseren Guide für die relevanten Stellen des tiefziehfähigen Designs zu Rate ziehen. Wir überprüfen die Zeichnung im Anschluss und passen diese auf Tiefziehfähigkeit an.\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003Cli>Sie wollen sich von Anfang an Ihr Tiefziehteil aus Kunststoff von Konstrukteuren mit langjähriger Erfahrung in allen Anwendungsbereichen konstruieren lassen?\u003Cul>\u003Cli>formary erstellt Ihre Daten und konstruiert nach Ihren Anforderungen optimale Geometrien zum Thermoformen.\u003C\u002Fli>\u003C\u002Ful>\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FDatenfreigabe_Laptop_Mockup_und_Konstruktion_8347a0859b.png\" alt=\"Datenerstellung\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Erhalten Sie schnell Ihr Muster\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Abhängig von Ihrem Zeitplan erhalten Sie Muster aus der entsprechend passenden Option. Es bieten sich 4 Optionen an, abhängig vom Sinn und Zweck der Muster:\u003C\u002Fp>\u003Cul>\u003Cli>Muster aus 3D-Druck-Werkzeug\u003C\u002Fli>\u003Cli>Muster aus Ureol-Werkzeug\u003C\u002Fli>\u003Cli>Muster aus Teilsegment Serien-Werkzeug\u003C\u002Fli>\u003Cli>Muster aus Serien-Werkzeug\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Mehr zu den Vorteilen, Nachteilen und Einsatzbereichen der unterschiedlichen Muster finden Sie unter \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fprototypen\">Prototypen\u003C\u002Fa> und unserem Blogbeitrag zum Thema \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Frapid-prototyping-moeglichkeiten-im-tiefziehen\">Rapid Prototyping.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FWerkzeug_und_Bemusterung_cd0eff947f.png\" alt=\"Muster erhalten\">\u003C\u002Ffigure>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Wir starten mir Ihrer Serienproduktion\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Nach erfolgreicher Bemusterung starten wir mit der Serienproduktion. Abhängig von Ihrem Material, der gewählten Werkzeugausführung, der Maschinenart zur Fertigung sowie der Stückzahl, beträgt die Vorlaufzeit in etwa \u003Cstrong>3-5 Wochen\u003C\u002Fstrong> von Freigabe\u002FBestellungseingang bis zur Auslieferung Ihrer Serie.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSerienfertigung_ede6049265.png\" alt=\"Serienproduktion starten\">\u003C\u002Ffigure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Fazit: Qualitätssicherung im Thermoforming durch genaue Prüfung der Konstruktionsdaten\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Konstruktionsdaten des Thermoformteils werden also nicht nur zur Herstellung des Werkzeugs erstellt, sondern vor allem auch für die kundenseitige Prüfung des Endprodukts. In diesem Stadium können etwaige hinzugekommene oder bisher übersehene Anforderungen einfach erkannt und dazu konstruiert werden. Dies gewährleistet einen effizienten Bemusterungs- und Projektprozess. \u003C\u002Fp>\u003Cp>formary sorgt dafür, dass Ihnen während des gesamten Projekts ein kompetenter Ansprechpartner zur Verfügung steht, um Fragen zu klären. Testen Sie es jetzt selbst aus und fragen Sie Ihr Kunststoff Tiefziehteil digital an. Jetzt \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fkonfigurator\">konfigurieren.\u003C\u002Fa>\u003C\u002Fp>","freigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten",{"id":865,"documentId":866,"createdAt":867,"updatedAt":868,"publishedAt":85,"locale":10,"title":869,"introduction":870,"content":871,"slug":872,"cover":1333,"seo":1373,"blog_author":1384,"blogcategory":1414,"inline_hubspot_form":85,"blocks":1458,"localizations":1496},{"id":1334,"documentId":1335,"name":1336,"alternativeText":1337,"caption":85,"width":363,"height":213,"formats":1338,"hash":1369,"ext":151,"mime":154,"size":1370,"url":1371,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1372,"updatedAt":1372,"publishedAt":1372},2578,"upnndlpyi92t3nkcnofeu6fv","Cost reduction in Thermoforming Banner.webp","Cost reduction in Thermoforming Banner",{"large":1339,"small":1345,"medium":1351,"xsmall":1357,"thumbnail":1363},{"ext":151,"url":1340,"hash":1341,"mime":154,"name":1342,"path":85,"size":1343,"width":212,"height":393,"sizeInBytes":1344},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Flarge_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a.webp","large_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a","large_Cost reduction in Thermoforming Banner.webp",51.27,51272,{"ext":151,"url":1346,"hash":1347,"mime":154,"name":1348,"path":85,"size":1349,"width":157,"height":375,"sizeInBytes":1350},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsmall_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a.webp","small_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a","small_Cost reduction in Thermoforming 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Banner.webp",22.96,22960,{"ext":151,"url":1364,"hash":1365,"mime":154,"name":1366,"path":85,"size":1367,"width":410,"height":411,"sizeInBytes":1368},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a.webp","thumbnail_Cost_reduction_in_Thermoforming_Banner_8311d6ec5a","thumbnail_Cost reduction in Thermoforming Banner.webp",7.18,7184,"Cost_reduction_in_Thermoforming_Banner_8311d6ec5a",71.73,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FCost_reduction_in_Thermoforming_Banner_8311d6ec5a.webp","2026-04-16T15:16:44.525Z",{"id":1374,"open_graph_title":1375,"open_graph_description":1376,"title":1375,"description":1376,"open_graph_image":1377},3369,"Guide to Cost Reduction in Thermoforming","Cost reduction in thermoforming ✅ Save material ✅ Optimize tools ✅ Lower unit costs ✅ Efficient design.",{"id":1334,"documentId":1335,"name":1336,"alternativeText":1337,"caption":85,"width":363,"height":213,"formats":1378,"hash":1369,"ext":151,"mime":154,"size":1370,"url":1371,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1372,"updatedAt":1372,"publishedAt":1372},{"large":1379,"small":1380,"medium":1381,"xsmall":1382,"thumbnail":1383},{"ext":151,"url":1340,"hash":1341,"mime":154,"name":1342,"path":85,"size":1343,"width":212,"height":393,"sizeInBytes":1344},{"ext":151,"url":1346,"hash":1347,"mime":154,"name":1348,"path":85,"size":1349,"width":157,"height":375,"sizeInBytes":1350},{"ext":151,"url":1352,"hash":1353,"mime":154,"name":1354,"path":85,"size":1355,"width":165,"height":220,"sizeInBytes":1356},{"ext":151,"url":1358,"hash":1359,"mime":154,"name":1360,"path":85,"size":1361,"width":173,"height":381,"sizeInBytes":1362},{"ext":151,"url":1364,"hash":1365,"mime":154,"name":1366,"path":85,"size":1367,"width":410,"height":411,"sizeInBytes":1368},{"id":1385,"documentId":1386,"createdAt":1387,"updatedAt":1388,"publishedAt":85,"locale":10,"role":1389,"name":1390,"email":1391,"phone":85,"meeting_url":85,"image":1392,"localizations":1409},53,"mt0jww5i0wn79z9rayvg1xae","2026-01-26T08:38:50.654Z","2026-03-02T13:19:27.857Z","Marketing Intern","Simon Andreß","simon.andress@formary.de",{"id":1393,"documentId":1394,"name":1395,"alternativeText":1396,"caption":85,"width":173,"height":523,"formats":1397,"hash":1404,"ext":151,"mime":154,"size":1405,"url":1406,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1407,"updatedAt":1407,"publishedAt":1408},2506,"h36uwikemmf0swm2k81muwe7","Simon Marketing Intern.webp","Simon Marketing Intern",{"thumbnail":1398},{"ext":151,"url":1399,"hash":1400,"mime":154,"name":1401,"path":85,"size":1402,"width":182,"height":182,"sizeInBytes":1403},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_Simon_Marketing_Intern_786abc18ac.webp","thumbnail_Simon_Marketing_Intern_786abc18ac","thumbnail_Simon Marketing Intern.webp",2.54,2542,"Simon_Marketing_Intern_786abc18ac",23.21,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FSimon_Marketing_Intern_786abc18ac.webp","2026-03-02T13:18:32.092Z","2026-03-02T13:18:32.093Z",[1410],{"id":1411,"documentId":1386,"createdAt":1412,"updatedAt":1413,"publishedAt":85,"locale":128,"role":1389,"name":1390,"email":1391,"phone":85,"meeting_url":85},55,"2026-01-26T09:58:43.228Z","2026-03-02T13:18:41.582Z",{"id":552,"documentId":553,"createdAt":554,"updatedAt":555,"publishedAt":85,"locale":10,"title":556,"slug":557,"description":558,"blogarticles":1415,"seo":1455,"localizations":1456},[1416,1417,1418,1419,1420,1421,1422,1423,1424,1425,1426,1427,1428,1429,1430,1431,1432,1433,1434,1435,1436,1437,1438,1439,1440,1441,1442,1443,1444,1445,1446,1447,1448,1449,1450,1451,1452,1453,1454],{"id":561,"documentId":562,"createdAt":563,"updatedAt":564,"publishedAt":85,"locale":10,"title":565,"introduction":566,"content":567,"slug":568},{"id":570,"documentId":571,"createdAt":572,"updatedAt":573,"publishedAt":85,"locale":10,"title":574,"introduction":575,"content":576,"slug":577},{"id":579,"documentId":580,"createdAt":581,"updatedAt":582,"publishedAt":85,"locale":10,"title":583,"introduction":584,"content":585,"slug":586},{"id":588,"documentId":589,"createdAt":590,"updatedAt":591,"publishedAt":85,"locale":10,"title":592,"introduction":593,"content":594,"slug":595},{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},{"id":606,"documentId":607,"createdAt":608,"updatedAt":609,"publishedAt":85,"locale":10,"title":610,"introduction":611,"content":612,"slug":613},{"id":615,"documentId":616,"createdAt":617,"updatedAt":618,"publishedAt":85,"locale":10,"title":619,"introduction":620,"content":621,"slug":622},{"id":624,"documentId":625,"createdAt":626,"updatedAt":627,"publishedAt":85,"locale":10,"title":628,"introduction":629,"content":630,"slug":631},{"id":633,"documentId":634,"createdAt":635,"updatedAt":636,"publishedAt":85,"locale":10,"title":637,"introduction":638,"content":639,"slug":640},{"id":642,"documentId":643,"createdAt":644,"updatedAt":645,"publishedAt":85,"locale":10,"title":646,"introduction":647,"content":648,"slug":649},{"id":651,"documentId":652,"createdAt":653,"updatedAt":654,"publishedAt":85,"locale":10,"title":655,"introduction":656,"content":657,"slug":658},{"id":660,"documentId":661,"createdAt":662,"updatedAt":663,"publishedAt":85,"locale":10,"title":664,"introduction":665,"content":666,"slug":667},{"id":669,"documentId":670,"createdAt":671,"updatedAt":672,"publishedAt":85,"locale":10,"title":673,"introduction":674,"content":675,"slug":676},{"id":678,"documentId":679,"createdAt":680,"updatedAt":681,"publishedAt":85,"locale":10,"title":682,"introduction":683,"content":684,"slug":685},{"id":687,"documentId":688,"createdAt":689,"updatedAt":690,"publishedAt":85,"locale":10,"title":691,"introduction":692,"content":693,"slug":694},{"id":696,"documentId":697,"createdAt":698,"updatedAt":699,"publishedAt":85,"locale":10,"title":700,"introduction":701,"content":702,"slug":703},{"id":381,"documentId":705,"createdAt":706,"updatedAt":707,"publishedAt":85,"locale":10,"title":708,"introduction":709,"content":710,"slug":711},{"id":713,"documentId":714,"createdAt":715,"updatedAt":716,"publishedAt":85,"locale":10,"title":717,"introduction":718,"content":719,"slug":720},{"id":722,"documentId":723,"createdAt":724,"updatedAt":725,"publishedAt":85,"locale":10,"title":726,"introduction":727,"content":728,"slug":729},{"id":731,"documentId":732,"createdAt":733,"updatedAt":734,"publishedAt":85,"locale":10,"title":735,"introduction":736,"content":737,"slug":738},{"id":740,"documentId":741,"createdAt":742,"updatedAt":743,"publishedAt":85,"locale":10,"title":744,"introduction":745,"content":746,"slug":747},{"id":749,"documentId":750,"createdAt":751,"updatedAt":752,"publishedAt":85,"locale":10,"title":753,"introduction":754,"content":755,"slug":756},{"id":758,"documentId":759,"createdAt":760,"updatedAt":761,"publishedAt":85,"locale":10,"title":762,"introduction":763,"content":764,"slug":765},{"id":767,"documentId":768,"createdAt":769,"updatedAt":770,"publishedAt":85,"locale":10,"title":771,"introduction":772,"content":773,"slug":774},{"id":776,"documentId":777,"createdAt":778,"updatedAt":779,"publishedAt":85,"locale":10,"title":780,"introduction":781,"content":782,"slug":783},{"id":785,"documentId":786,"createdAt":787,"updatedAt":788,"publishedAt":85,"locale":10,"title":789,"introduction":790,"content":791,"slug":792},{"id":794,"documentId":795,"createdAt":796,"updatedAt":797,"publishedAt":85,"locale":10,"title":798,"introduction":799,"content":800,"slug":801},{"id":435,"documentId":436,"createdAt":437,"updatedAt":438,"publishedAt":85,"locale":10,"title":439,"introduction":440,"content":441,"slug":442},{"id":804,"documentId":805,"createdAt":806,"updatedAt":807,"publishedAt":85,"locale":10,"title":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Asked Questions About Cost Reduction in Thermoforming",[1463,1467,1471,1475],{"id":1464,"title":1465,"content":1466},9581,"When is a multi-cavity mold or mold optimization worthwhile?","\u003Cp>A multi-cavity mold or mold optimization is particularly worthwhile for medium to high production volumes. As production volume increases, the investment costs are spread out more effectively, while more efficient molds and shorter cycle times significantly reduce unit costs.\u003C\u002Fp>",{"id":1468,"title":1469,"content":1470},9582,"Why is material selection so crucial?","\u003Cp>The material accounts for a large portion of the total costs. An optimized selection can therefore lead to direct savings.\u003C\u002Fp>",{"id":1472,"title":1473,"content":1474},9583,"What should be considered when designing the part?","\u003Cp>The part should ideally not have complex geometries or elements such as sliders and undercuts. Such features make the mold more expensive.\u003C\u002Fp>",{"id":1476,"title":1477,"content":1478},9584,"What makes up the total costs in thermoforming?","\u003Cp>The total costs in thermoforming consist primarily of tooling costs, material costs, and manufacturing costs. Energy costs and labor costs are also included. Depending on the component and quantity, these components can vary in their relative importance.\u003C\u002Fp>\n\n\u003Cp>Learn more in our article on the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">Relationship Between Unit Costs and Tooling Costs in Thermoforming.\u003C\u002Fa>\u003C\u002Fp>",{"__component":430,"id":1480,"title":935,"variant":289,"cta_button":85,"blogarticles":1481,"style":1494},732,[1482,1483,1492,1493],{"id":856,"documentId":857,"createdAt":858,"updatedAt":859,"publishedAt":85,"locale":10,"title":860,"introduction":861,"content":862,"slug":863},{"id":1484,"documentId":1485,"createdAt":1486,"updatedAt":1487,"publishedAt":85,"locale":10,"title":1488,"introduction":1489,"content":1490,"slug":1491},347,"k9iwpg2wi9raza5vmpyikuuc","2026-01-13T15:51:47.043Z","2026-06-02T16:45:02.555Z","5 Levers formary Uses to Reduce Thermoforming Costs","Procuring plastic thermoformed parts can be a complex and costly process, especially for demanding applications or intricate designs. That’s why we are outlining the five key levers formary uses to lower the thermoforming costs of plastic components.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Reducing thermoforming costs – Key points at a glance\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>\u003Cstrong>formary\u003C\u002Fstrong> reduces your \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Funit-and-tooling-costs-in-thermoforming\">thermoforming costs\u003C\u002Fa> through five targeted measures:\u003C\u002Fp>\u003Cul>\u003Cli>\u003Cstrong>Early design support:\u003C\u002Fstrong> Avoid cost traps right from the design phase.\u003C\u002Fli>\u003Cli>\u003Cstrong>Optimal choice of materials:\u003C\u002Fstrong> Efficient thermoplastics reduce material consumption and costs.\u003C\u002Fli>\u003Cli>\u003Cstrong>Digital process optimisation:\u003C\u002Fstrong> A user-friendly platform for fast, transparent procurement.\u003C\u002Fli>\u003Cli>\u003Cstrong>Automated supplier matching:\u003C\u002Fstrong> Find the perfect manufacturers within 24 hours.\u003C\u002Fli>\u003Cli>\u003Cstrong>Diversification within the network:\u003C\u002Fstrong> Avoiding supply bottlenecks and keeping prices stable.\u003C\u002Fli>\u003C\u002Ful>\u003Cp>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fconfigurator\">→ Enquire now\u003C\u002Fa>\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">1. How does formary optimise thermoforming costs right from the design stage?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>By getting involved at an early stage in the design process in accordance with the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002F3d-services\u002Fdfm-analyse\">Design for Manufacturing (DFM) principle\u003C\u002Fa>, formary identifies cost drivers as early as the design phase. We offer advice on:\u003C\u002Fp>\u003Cul>\u003Cli>Choice of materials\u003C\u002Fli>\u003Cli>Design\u003C\u002Fli>\u003Cli>Tool planning\u003C\u002Fli>\u003C\u002Ful>\u003Cp>to develop a cost-optimised deep-drawn part. This ensures the best combination of material, stability and tool design. You can find out more about the design of deep-drawn parts in our \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fdesign-guide\">Design Guide.\u003C\u002Fa>\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">2. How does choosing the right material reduce thermoforming costs?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Choosing the right \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\">material\u003C\u002Fa> is crucial for optimising costs in \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fplastic-thermoforming\">plastic deep-drawing. \u003C\u002Fa>By analysing material properties and their behaviour during the deep-drawing process, we can recommend materials that offer high formability whilst reducing material consumption. formary analyses the specific requirements of each project and selects plastics that are both cost-effective and high-performance.\u003C\u002Fp>\u003Ch3>\u003Cspan style=\"color:#005250;\">What thermoplastics does formary work with?\u003C\u002Fspan>\u003C\u002Fh3>\u003Ch4>All-rounders & technical thermoplastics\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fabs-plastic\">ABS\u003C\u002Fa>: A versatile material with good mechanical and thermal properties (–40°C to 75°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fasa-plastic\">ASA\u003C\u002Fa>: Modified ABS, UV- and weather-resistant (–20°C to 90°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpc-plastic\">PC\u003C\u002Fa> (polycarbonate): Highly heat-resistant, highly transparent, electrical insulator (–100°C to 130°C)\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Transparent plastics\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpmma-plastic\">PMMA\u003C\u002Fa> (Plexiglas): Crystal-clear appearance, rigid\u002Fbrittle, weather-resistant (–40°C to 70°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-a-plastic\">PET-A\u003C\u002Fa>: Cost-effective, highly transparent, particularly suitable for packaging (–10°C to 60°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpet-g-plastic\">PET-G\u003C\u002Fa>: Modified PET-A, very high moulding precision and transparency (–40°C to 63°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpvc-plastic\">PVC\u003C\u002Fa> (rigid): High rigidity, strength, transparency, chemical resistance (–5°C to 65°C)\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Chemical-resistant plastics\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fhd-pe-plastic\">HD-PE\u003C\u002Fa>: Resistant to oils and chemicals, low hardness, good elasticity (–50°C to 85°C)\u003C\u002Fli>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fpp-plastic\">PP\u003C\u002Fa>: Very soft, very stretchy, particularly suitable for packaging (0°C to 100°C)\u003C\u002Fli>\u003C\u002Ful>\u003Ch4>Standard\u002Fmass-produced plastics\u003C\u002Fh4>\u003Cul>\u003Cli>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fmaterials\u002Fps-plastic\">PS\u003C\u002Fa> (polystyrene): Versatile, medium hardness and strength, cost-effective (–20°C to 60°C)\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">How can the configurator help with choosing materials?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Using the automated material recommendations in the \u003C\u002Fspan>\u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fkonfigurator\">\u003Cspan style=\"color:hsl(0,0%,0%);\">configurator\u003C\u002Fspan>\u003C\u002Fa>\u003Cspan style=\"color:hsl(0,0%,0%);\">, you can receive suggestions for the most suitable thermoplastic for your thermoforming project, which we will, of course, verify once again. Factors such as material costs, availability, processability and suitability for the thermoformed product are taken into account.\u003C\u002Fspan>\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \u003Cp>ℹ️ Find out how the choice of material affects the overall cost of your thermoforming project in our new \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fwhitepaper-ebooks\u002Fmaterialguide-1\">whitepaper\u003C\u002Fa>.\u003C\u002Fp>\u003C\u002Fdiv>\u003C\u002Fdiv>\u003Ch2>\u003Cspan style=\"color:#005250;\">3. How does the platform save time and money?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>With our guided configurator, you can configure \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fproducts\">thermoformed products\u003C\u002Fa> in just a few clicks. The \u003Cstrong>customer portal\u003C\u002Fstrong> offers full transparency regarding:\u003C\u002Fp>\u003Cul>\u003Cli>Status tracking\u003C\u002Fli>\u003Cli>Changes to specifications\u003C\u002Fli>\u003Cli>direct communication with the project manager\u003C\u002Fli>\u003Cli>quick approvals\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">What are the benefits of the formary platform?\u003C\u002Fspan>\u003C\u002Fh3>\u003Cul>\u003Cli>Less coordination required\u003C\u002Fli>\u003Cli>Faster projects\u003C\u002Fli>\u003Cli>Lower procurement costs\u003C\u002Fli>\u003C\u002Ful>\u003Ch3>\u003Cspan style=\"color:#005250;\">Customer portal\u003C\u002Fspan>\u003C\u002Fh3>\u003Cp>Once an order has been placed, you can track the project status, manage approvals and communicate directly with the project manager via the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Faccount\u002Finquiries\">customer portal\u003C\u002Fa>. The portal thus ensures up-to-date transparency in project management and precise control over enquiries and orders, saving both time and thermoforming costs.\u003C\u002Fp>\u003Cp>We explain more about how to use the formary platform in our \u003Ca href=\"https:\u002F\u002Fwww.youtube.com\u002Fwatch?v=53kReMurlqU&t=15s\">webinar.\u003C\u002Fa>\u003C\u002Fp>\u003Ch2>\u003Cspan style=\"color:#005250;\">4. How does formary’s supplier matching service work?\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>formary’s matching algorithm matches your requirements in real time with a verified network of suppliers: \u003C\u002Fp>\u003Cul>\u003Cli>Taking into account \u003Cstrong>machinery\u003C\u002Fstrong>, \u003Cstrong>stock\u003C\u002Fstrong>, \u003Cstrong>skills\u003C\u002Fstrong>\u003C\u002Fli>\u003Cli>Access to the capacity of certified DACH-based companies\u003C\u002Fli>\u003Cli>\u003Cstrong>Instant quote\u003C\u002Fstrong> usually within 24 hours\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Our matching algorithm automatically selects the best manufacturer from our network. The benefits for you are:\u003C\u002Fp>\u003Cul>\u003Cli>Access to capacity from the DACH region at any time\u003C\u002Fli>\u003Cli>Instant quote within 24 hours\u003C\u002Fli>\u003C\u002Ful>\u003Ch2>\u003Cspan style=\"color:#005250;\">5. Cost savings in deep drawing through diversification and spreading your requirements across the supplier network\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>Since the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fmaterial-shortage-how-formary-can-help\">supply chain issues\u003C\u002Fa> in 2022 – which were originally triggered by the COVID-19 crisis – establishing secondary sources of supply and alternative suppliers has become a common strategy for companies to reduce dependencies and the risk of delivery failures. formary automates this diversification process and distributes projects across a broad network of suppliers. This means that you can request plastic thermoformed parts from formary at any time, with consistent quality, and have them delivered within the specified delivery times.\u003C\u002Fp>\u003Cp>You can find further tips on how to reduce costs in the \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fen\u002Fblog\u002Fguide-to-cost-reduction-in-thermoforming\">Guide to Cost Reduction in Deep Drawing\u003C\u002Fa>.\u003C\u002Fp>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Reducing delivery costs with formary – A summary\u003C\u002Fspan>\u003C\u002Fh2>\u003Cp>By combining these five factors, formary can significantly reduce thermoforming costs and thereby improve efficiency in the procurement of plastic thermoformed parts. This enables the company to offer high-quality products at relatively low cost, delivered quickly, automatically and reliably. \u003C\u002Fp>\u003Cp>For more information on how formary can help you reduce your procurement costs, please watch our webinar on \u003Ca href=\"https:\u002F\u002Fyoutu.be\u002FCZboBENMNjI?si=_X7OK1GBMi_doxMT&t=2260\">procurement with formary.\u003C\u002Fa>\u003C\u002Fp>","5-levers-formary-uses-to-reduce-thermoforming-costs",{"id":839,"documentId":840,"createdAt":841,"updatedAt":842,"publishedAt":85,"locale":10,"title":843,"introduction":844,"content":845,"slug":846},{"id":597,"documentId":598,"createdAt":599,"updatedAt":600,"publishedAt":85,"locale":10,"title":601,"introduction":602,"content":603,"slug":604},{"id":1495,"background":943,"border":85},3264,[1497],{"id":1498,"documentId":866,"createdAt":1499,"updatedAt":1500,"publishedAt":85,"locale":128,"title":1501,"introduction":1502,"content":1503,"slug":1504},651,"2026-04-16T11:46:58.902Z","2026-05-29T10:43:14.476Z","Leitfaden: Top 5 Tipps zur Kostenreduktion im Thermoformen","Die Kosten im Kunststoff Tiefziehen werden vor allem durch Konstruktion, Materialwahl und Werkzeugkonzeption bestimmt. Viele Kostentreiber sind dabei nicht auf den ersten Blick erkennbar und werden oft erst spät im Entwicklungsprozess bemerkt. Genau hier entstehen häufig unnötige Kosten, die sich mit den richtigen Maßnahmen vermeiden lassen.","\u003Ch2>Kosten im Thermoformen reduzieren - Das Wichtigste in Kürze\u003C\u002Fh2>\u003Cul>\u003Cli>Bauteilkonstruktion, Materialwahl und Werkzeugdesign sind die größten Hebel zur Kostenreduktion\u003C\u002Fli>\u003Cli>Fertigungsoptimierte Konstruktion senkt die Stückkosten nachhaltig\u003C\u002Fli>\u003Cli>Reduzierter Materialeinsatz minimiert Kosten direkt\u003C\u002Fli>\u003Cli>Effiziente Werkzeuge verbessern die Wirtschaftlichkeit\u003C\u002Fli>\u003Cli>Frühe Berücksichtigung in der Entwicklungsphase ist entscheidend\u003C\u002Fli>\u003C\u002Ful>\u003Chr>\u003Ch2>Wie entstehen hohe Kosten im Thermoformen?\u003C\u002Fh2>\u003Cp>Die größten Kostentreiber im \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Ftiefziehen-kunststoff\">Kunststoff Thermoformen\u003C\u002Fa> sind für viele Unternehmen nicht auf den ersten Blick zu erkennen. Besonders ohne Erfahrung in Konstruktion und Werkzeugdesign werden sie häufig erst sichtbar, wenn Anpassungen bereits mit hohem Aufwand und zusätzlichen Kosten verbunden sind.\u003C\u002Fp>\u003Cp>Neben dem Materialeinsatz spielen vor allem die Werkzeugkomplexität und die damit verbundenen Prozessschritte eine wichtige Rolle. Oft wird unterschätzt, dass bereits kleine Anpassungen im Design große Auswirkungen haben können. Genau hier liegt das größte Potenzial, Kosten im Thermoformen zu reduzieren. Wir unterstützen Sie dabei, Ihre Bauteile von Beginn an kostenoptimiert zu designen.\u003C\u002Fp>\u003Ch2>5 Tipps für die Kostenreduktion im Thermoformen\u003C\u002Fh2>\u003Cp>Diese Tipps können schon zum Start Ihres \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fprojektplanung-im-thermoforming\">Tiefziehprojekts \u003C\u002Fa>bedacht werden, um den Gesamtpreis Ihrer Kunststoff Tiefziehteile möglichst ökonomisch zu halten.\u003C\u002Fp>\u003Cp>Bei \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Ftiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugen \u003C\u002Fa>haben Sie folgende Möglichkeiten:\u003C\u002Fp>\u003Cul>\u003Cli>Mehrere Teile mit einem Werkzeug produzieren\u003C\u002Fli>\u003Cli>Bewegliche Teile vermeiden\u003C\u002Fli>\u003Cli>Mehrfach-Nutzen Werkzeuge verwenden\u003C\u002Fli>\u003C\u002Ful>\u003Cp>Auch die Materialwahl bestimmt, wie sich die Kosten im Thermoformen gestalten. Daher sollten Sie:\u003C\u002Fp>\u003Cul>\u003Cli>Material bewusst und bedarfsgerecht auswählen\u003C\u002Fli>\u003Cli>Eingefärbtes Halbzeug nutzen\u003C\u002Fli>\u003Cli>den Materialeinsatz durch intelligente Konstruktion reduzieren\u003C\u002Fli>\u003C\u002Ful>\u003Cp>In den nächsten Abschnitten erklären wir Ihnen diese Schritte im Detail.\u003C\u002Fp>\u003Ch3>1. Produzieren Sie mehrere Teile mit einem Werkzeug\u003C\u002Fh3>\u003Cp>Ein großer Hebel zur Stückkostenreduktion ist die effiziente Nutzung des Werkzeugs. Ziel ist es, pro Takt einen möglichst hohen Ausstoß zu erreichen. Mehrfach-Nutzen-Werkzeuge sind im Thermoformen gängige Praxis und ermöglichen es, mehrere identische Bauteile gleichzeitig zu produzieren. Aber auch die Kombination unterschiedlicher Komponenten in einem Werkzeug bietet erhebliches Einsparpotenzial. Wie das in der Praxis aussieht, erfahren Sie in unserer \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fcase-studies\u002Fnaext\">Case Study mit NAEXT.\u003C\u002Fa>\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:1140\u002F814;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGrafik_Mehrfach_Nutzen_Werkzeug_84be103d5a.webp\" alt=\"Grafik Mehrfach-Nutzen-Werkzeug\" width=\"1140\" height=\"814\">\u003Cfigcaption>Grafische Abbildung eines Mehrfach-Nutzen-Werkzeugs\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Ch3>2. Vermeiden Sie bewegliche Teile im Werkzeug\u003C\u002Fh3>\u003Cp>Komplexe Bauteilgeometrien, insbesondere Hinterschnitte, führen dazu, dass im Werkzeug bewegliche Elemente notwendig werden. Diese erhöhen die Tiefziehkosten und den Wartungsaufwand erheblich. Deshalb sollten Sie bereits in der \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fgestaltungsregeln-bei-kunststoff-tiefziehteilen\">Konstruktion\u003C\u002Fa> prüfen, ob sich das Werkstück so anpassen lässt, dass diese Komplexität entfällt.\u003C\u002Fp>\u003Cp>\u003Cstrong>Typische Optimierungen sind:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Verzicht auf Hinterschnitte\u003C\u002Fli>\u003Cli>Anpassung von Entformungsschrägen\u003C\u002Fli>\u003Cli>Vereinfachung der Geometrie\u003C\u002Fli>\u003C\u002Ful>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:745\u002F849;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FGrafik_Hinterschnitt_681155f614.webp\" alt=\"Grafik Hinterschnitt\" width=\"745\" height=\"849\">\u003Cfigcaption>Abbildung eines Hinterschnitts.\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 Hinterschnitte werden durch einklappbare Elemente am Werkzeug ermöglicht. Das Werkzeug ist mit Schiebern ausgestattet, die beim Entformen “wegklappen” (Klappen-Werkzeug). Dadurch wird der Entformvorgang komplexer und das Werkzeug kostenintensiver. Daher sollten sie immer auf ein Minimum reduziert werden. \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch3>3. Wählen Sie das Material bewusst und bedarfsgerecht aus\u003C\u002Fh3>\u003Cp>Ein häufiger Fehler in der Praxis ist die Wahl eines \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fkunststoff-lackieren-das-ist-bei-der-lackierung-von-thermoplasten-zu-beachten\">Materials\u003C\u002Fa>, das mehr kann als eigentlich notwendig ist. Diese sogenannte „Überdimensionierung“ führt unnötig zu höheren Kosten im Thermoformen. Stattdessen sollte die Materialauswahl konsequent nach dem Bottom-Up-Prinzip erfolgen: Es wird genau das Material gewählt, das die Anforderungen exakt erfüllt.\u003C\u002Fp>\u003Cp>Das sorgt für eine wirtschaftlichere Lösung bei gleicher Funktionalität.\u003C\u002Fp>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 Wie Sie das passende Material für Ihr Projekt auswählen, erfahren Sie in unserem Whitepaper \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fwhitepaper-ebooks\u002Fin-6-schritten-zum-richtigen-kunststoff-fuer-ihr-tiefziehprojekt\"> In 6 Schritten zum richtigen Kunststoff für Ihr Tiefziehprojekt. \u003C\u002Fa> \n    \u003C\u002Fp>\u003C\u002Fdiv>\u003Ca>\n\u003C\u002Fa>\u003C\u002Fdiv>\u003Ch3>4. Nutzen Sie eingefärbtes Halbzeug für farbige Teile\u003C\u002Fh3>\u003Cp> \u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:2000\u002F1498;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FTiefgezogene_Kunststoffwanne_rot_nachlackiert_77d2c1c31f.webp\" alt=\"Tiefgezogene Kunststoffwanne rot nachlackiert\" width=\"2000\" height=\"1498\">\u003C\u002Ffigure>\u003Cp>In vielen Projekten erfolgt die Farbgebung erst nachgelagert im Prozess, wie etwa durch \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002Fblog\u002Fkunststoff-lackieren-das-ist-bei-der-lackierung-von-thermoplasten-zu-beachten\">Kunststofflackierung.\u003C\u002Fa> Das bedeutet einen zusätzlichen Arbeitsschritt, der Zeit und Geld kostet.\u003C\u002Fp>\u003Cp>Wird stattdessen bereits eingefärbtes Halbzeug eingesetzt, kann dieser Schritt entfallen. Voraussetzung ist allerdings, dass die Stückzahlen und die Lieferkette die Beschaffung zulassen.\u003C\u002Fp>\u003Ch3>5. Reduzieren Sie den Materialeinsatz durch intelligente Konstruktion\u003C\u002Fh3>\u003Cp>Das Material ist einer der größten Kostenfaktoren im Thermoformen. Deshalb lohnt es sich besonders, hier anzusetzen. Durch eine clevere Konstruktion kann die Materialstärke reduziert werden, ohne die Stabilität zu gefährden. Häufig kommen dabei Verstärkungsstrukturen wie Rippen zum Einsatz.\u003C\u002Fp>\u003Cfigure class=\"image\">\u003Cimg style=\"aspect-ratio:819\u002F855;\" src=\"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002FRippen_am_Tiefziehteil_Grafik_7893d14406.webp\" alt=\"Rippen am Tiefziehteil Grafik\" width=\"819\" height=\"855\">\u003Cfigcaption>Rippen am Tiefziehteil für mehr Stabilität bei geringer Materialstärke\u003C\u002Ffigcaption>\u003C\u002Ffigure>\u003Cp>\u003Cstrong>Typische Effekte sind:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>geringerer Materialverbrauch\u003C\u002Fli>\u003Cli>niedrigere Stückkosten\u003C\u002Fli>\u003Cli>gleichbleibende Bauteilqualität\u003C\u002Fli>\u003C\u002Ful>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C\u002Fstyle>\n\n\u003Cdiv class=\"c-container\"> \n        \u003Cp> 💡 Bei einzubringenden Rippen oder auch Verstrebungen gilt es zu beachten: Zu viele Querrippen mit geringem Abstand beeinflussen das Ziehverhältnis negativ und die Distanz zwischen einzelnen Querrippen muss mindestens so groß sein wie deren Tiefe.\n    \u003C\u002Fp>\n\n\u003C\u002Fdiv>\n\u003C\u002Fdiv>\u003Chr>\u003Ch2>Fazit: Die Reduktion von Kosten im Thermoformen beginnt bei der richtigen Konzeption\u003C\u002Fh2>\u003Cp>Die größten Einsparpotenziale im Tiefziehen entstehen nicht erst in der Produktion, sondern bereits in der Entwicklungs- und Konstruktionsphase. Wer frühzeitig auf eine materialeffiziente Auslegung, einfache Geometrien und eine werkzeuggerechte Konstruktion achtet, legt den Grundstein für dauerhaft niedrige Stückkosten.\u003C\u002Fp>\u003Cp>\u003Cstrong>Tipp:\u003C\u002Fstrong> Mit unserer \u003Ca href=\"https:\u002F\u002Fwww.formary.de\u002F3d-services\u002Fdfm-analyse\">DfM-Analyse\u003C\u002Fa> Software prüfen wir Ihre Daten auf Tiefziehbarkeit und ermitteln für Sie das beste Kosten-Nutzen Verhältnis.\u003C\u002Fp>","leitfaden-zur-kostenreduktion-im-tiefziehen",{"id":1506,"background":943,"border":85},3331,{"__component":913,"id":1508,"title":1509,"variant":253,"first_accordion_open":425,"accordions":1510},1514,"Frequently asked questions about the whitepaper",[1511,1515,1519,1523,1527,1531],{"id":1512,"title":1513,"content":1514},9923,"What exactly does the whitepaper cover?","\u003Cp>The whitepaper explains automated DfM analysis for plastic thermoformed parts. You learn how to upload CAD data, which parameters are checked, and how the evaluation works. The focus is on practical application: reducing iteration cycles, identifying critical wall thicknesses early, and avoiding costly tool modifications.\u003C\u002Fp>",{"id":1516,"title":1517,"content":1518},9924,"Who is the whitepaper relevant for?","\u003Cp>For all stakeholders in development and procurement of plastic thermoformed parts: design engineers, purchasers, project managers, quality managers, as well as management and production who want to reduce costs and increase planning certainty.\u003C\u002Fp>",{"id":1520,"title":1521,"content":1522},9925,"What specific content is included?","\u003Cp>Included are:\u003C\u002Fp>\n\u003Cul>\n\u003Cli>Complete DfM workflow description\u003C\u002Fli>\n\u003Cli>Critical design features such as wall thicknesses and draft angles\u003C\u002Fli>\n\u003Cli>Optimization strategies\u003C\u002Fli>\n\u003Cli>Cost-saving potential and use cases in robotics, medical technology, electronics, and industrial components.\u003C\u002Fli>\n\u003C\u002Ful>",{"id":1524,"title":1525,"content":1526},9926,"Why is the download worthwhile?","\u003Cp>You're probably losing time and money through avoidable design errors that are only discovered late. The whitepaper shows a method with which companies halve their development cycles. 20-30 minutes reading time for immediately applicable knowledge.\u003C\u002Fp>",{"id":1528,"title":1529,"content":1530},9927,"Do I need technical background knowledge?","\u003Cp>Basic knowledge in designing plastic thermoformed parts and CAD is helpful but not required. The whitepaper explains all concepts clearly. Purchasers, project managers, or management also benefit from the strategic insights.\u003C\u002Fp>",{"id":1532,"title":1533,"content":1534},9928,"How quickly can I use the DfM check?","\u003Cp>Immediately after reading. Simply book a \u003Ca href=\"https:\u002F\u002Fmeetings.hubspot.com\u002Fmoritz-bittner-formary\u002Fdfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse\">demo\u003C\u002Fa> and we'll go through the data together with you.\u003C\u002Fp>",{"__component":1536,"id":410,"title":1537,"webinare":1538},"page-template.webinare","Additional whitepapers & guides",[1539,1585,1642],{"id":1540,"title":1541,"date":85,"link":1542,"link_text":1543,"content":1544,"image":1545},893,"Material Guide for Plastic Thermoformed Parts (1\u002F2)","\u002Fwhitepaper-ebooks\u002Fmaterialguide-1","Download Whitepaper","\u003Cp>Learn how different thermoplastics influence the performance of thermoformed parts and which industry-specific requirements and factors play a role in selecting the suitable plastic.\u003C\u002Fp>\u003Cp>\u003Cstrong>What to expect:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>Impact of material on total costs\u003C\u002Fli>\u003Cli>Overview of thermoformable thermoplastics\u003C\u002Fli>\u003Cli>Criteria for distinguishing thermoplastics\u003C\u002Fli>\u003Cli>Specialization of thermoformable plastics\u003C\u002Fli>\u003Cli>Industry-specific standards\u003C\u002Fli>\u003C\u002Ful>",{"id":1546,"documentId":1547,"name":1548,"alternativeText":1548,"caption":85,"width":363,"height":213,"formats":1549,"hash":1580,"ext":151,"mime":154,"size":1581,"url":1582,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1583,"updatedAt":1584,"publishedAt":1583},2526,"qoaxvpk2w7q2enu2gc21gi8j","Materilguide 1\u002F2 Mockup Eng",{"large":1550,"small":1556,"medium":1562,"xsmall":1568,"thumbnail":1574},{"ext":151,"url":1551,"hash":1552,"mime":154,"name":1553,"path":85,"size":1554,"width":212,"height":393,"sizeInBytes":1555},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Flarge_2_Mockup_Eng_b944e7d245.webp","large_2_Mockup_Eng_b944e7d245","large_Materilguide 1\u002F2 Mockup Eng",27.14,27136,{"ext":151,"url":1557,"hash":1558,"mime":154,"name":1559,"path":85,"size":1560,"width":157,"height":375,"sizeInBytes":1561},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fsmall_2_Mockup_Eng_b944e7d245.webp","small_2_Mockup_Eng_b944e7d245","small_Materilguide 1\u002F2 Mockup Eng",10.61,10608,{"ext":151,"url":1563,"hash":1564,"mime":154,"name":1565,"path":85,"size":1566,"width":165,"height":220,"sizeInBytes":1567},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fmedium_2_Mockup_Eng_b944e7d245.webp","medium_2_Mockup_Eng_b944e7d245","medium_Materilguide 1\u002F2 Mockup Eng",16.13,16128,{"ext":151,"url":1569,"hash":1570,"mime":154,"name":1571,"path":85,"size":1572,"width":173,"height":381,"sizeInBytes":1573},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fxsmall_2_Mockup_Eng_b944e7d245.webp","xsmall_2_Mockup_Eng_b944e7d245","xsmall_Materilguide 1\u002F2 Mockup Eng",8.17,8174,{"ext":151,"url":1575,"hash":1576,"mime":154,"name":1577,"path":85,"size":1578,"width":410,"height":411,"sizeInBytes":1579},"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002Fthumbnail_2_Mockup_Eng_b944e7d245.webp","thumbnail_2_Mockup_Eng_b944e7d245","thumbnail_Materilguide 1\u002F2 Mockup Eng",1.87,1866,"2_Mockup_Eng_b944e7d245",44.2,"https:\u002F\u002Ffsn1.your-objectstorage.com\u002Fformary-de-production-cms\u002F2_Mockup_Eng_b944e7d245.webp","2026-03-30T15:26:58.133Z","2026-04-07T16:35:34.329Z",{"id":1586,"title":1587,"date":85,"link":1588,"link_text":1543,"content":1589,"image":1590},894,"Finding the Right Supplier for Plastic Parts","\u002Fwhitepaper-ebooks\u002Fsupplier-guide","\u003Cp>Learn how to find the right supplier for your thermoforming project. This way you can prevent unreliable suppliers, poor consulting, long response times, and poor quality of plastic parts.\u003C\u002Fp>\u003Cp>\u003Cstrong>What to expect:\u003C\u002Fstrong>\u003C\u002Fp>\u003Cul>\u003Cli>10 tips for supplier search\u003C\u002Fli>\u003Cli>Advantages of the formary supplier network\u003C\u002Fli>\u003Cli>Save time and effort\u003C\u002Fli>\u003Cli>Transparent processes\u003C\u002Fli>\u003Cli>Manufacturing and post-processing methods\u003C\u002Fli>\u003C\u002Ful>",{"id":1591,"documentId":1592,"name":1593,"alternativeText":1594,"caption":16,"width":363,"height":213,"formats":1595,"hash":1636,"ext":304,"mime":307,"size":1637,"url":1638,"previewUrl":85,"provider":187,"provider_metadata":85,"createdAt":1639,"updatedAt":1640,"publishedAt":1641},2117,"dn34ak9rzgdqhrtr1sbju1w7","Lieferantenguide Banner english.png","Lieferantenguide Banner 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