Successful design of any formed part depends on a great number of factors. There are, however, just a few that should be considered in the beginning phases of your design process. After the basic design is roughly determined, we can review your concept and suggest additional ideas to maximize processability, dimensional control, and part performance. Material selection can greatly alter the overall performance and cost of the final product. It is at this stage that these factors can be addressed. Solid models expedite the design and tool building processes.

MOLDS: The ability to make very large parts with lower cost aluminum tooling can employ having one side of the part (mold side) in many forming applications being controlled. Tolerances that are extremely tight are one of the major contributing factors in cost escalation. It is best to consider which specific areas of the part need to be maintained as "critical" and how tight they must be for the intended use. Mating parts and dimensional stacking problems must also be considered at this stage. Determining tolerance and fits helps guide which of a number of thermoforming techniques and tooling (male vs. female) will be considered. Compression molding (tools on both sides) and twin sheeting options can be considered as well. Pressure forming provides another level of dimensional control and cosmetic opportunity. Pressure forming in multiple cavities often rivals the economics of injection molding.

WALL THICKNESS: Overall wall thickness in the cross-sectional area will vary in the single side thermoforming process. Failure to observe this basic rule leads to increased tooling costs, reduced production efficiencies, reduced tolerance control, etc.

TOLERANCES: are dependant upon a great number of factors including shape, material, overall size among others.