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USA, Florida, Winter Haven, 33880-4353, 654 Post Ave SW
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John Salva
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Advantage Plastics, Company
Thermoforming is the process of heating thermoplastic sheet, which is extruded from pellet form, to a pliable state. When the sheet reaches its forming temperature, it is removed from the heat source. A mold then enters the softened sheet. The sheet is sealed on the edge of the mold and vacuum is applied to evacuate the air trapped between the sheet and the mold. The atmospheric pressure then forces the sheet against the mold. The cooling process begins, both internally and externally. When the part reaches a cooled state or its set temperature, it is removed from the mold, trimmed, the finishing is completed on it per print, and it is then ready for shipment.
Cast aluminum molds are generally the best for thermoforming. They offer the best heat transfer, which allows us to accurately control the cycle times, part shrinkage, and part warpage. Consistency in the forming process is essential in the final trimming and quality control.
Molds, depending on the size and geometry, can be made in single or multiple cavities. There are also male and female molds. These are determined by dimensional requirements of the customer, Aesthetic requirements, and compatibility with mating parts in assemblies.
Material comes in various types of grain. The grain is usually only on one side of the sheet and is almost always formed with the smooth side against the mold. Forming the sheet with the grain on the mold side almost always washes the grain out leaving an unpleasant appearance. For the customer that wants grain on both sides, wants to enhance the grain, or the part must have a grained finish on a female mold, textured molds are an option. Though these molds can be quite expensive, they produce parts with exceptional quality.
Variations of the basic process give us the various techniques used in thermoforming. They are: snapback forming, plug assist forming, billow forming, pressure forming, and twin sheet forming. The technique used on any particular job depends on several factors. These can be discussed on a part by part basis.
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Pressure Forming can give the appearance of an injection molded or structural foam part with a fraction of the tooling cost. Pressure Forming produces the most detail of the Thermoforming processes. As with any kind of thermoforming, Plastic Pressure Forming starts with sheet plastic being heated...
Group: Products from plastic shaped
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Vacuum forming, commonly known as vacuforming, is a simplified version of thermoforming, in which a sheet of plastic is heated to a forming temperature, stretched onto or into a single-surface mold, and held against the mold by applying vacuum between the mold surface and the sheet.
The vacuum...
Group: Products from plastic
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Thermoformed products can be virtually indistinguishable from injection molded products. Thermoforming has less set up and lead time, so it is ideal for projects that have to be manufactured in a hurry.
The cost advantage of thermoformed parts compared with injection molding depends on the...
Group: Plastic products