Upgrading to thermoforming from metal has many advantages that provide the aesthetics required in today’s market at minimal cost.
There are several benefits for converting metal to a thermoformed part. The four most important (benefits) are:
- Design Flexibility
- Material advantages
- The more complex the geometry of the part’s design the greater the cost savings. A customer may experience a cost savings of up to 50 percent on a conversion to plastic on a complex part.
- As the part’s complexity and the production volumes increase the advantages of thermoforming grows exponentially. In a metal fabrication, investments in component ancillary tooling may be needed (stamping dies) to achieve shipment releases and cost reductions.
In-direct benefits include:
- Decrease in weight will reduce assembly cost (one assembler rather than two).
- Customer perception of an advanced product due to the flexibility of design and materials available to General Plastics.
- Thermoforming resins allow engineers to obtain the properties required, while allowing designers the flexibility to achieve the aesthetics required and reduces the cost and weight of the product.
- Depending on the metal alloy, thermoformed plastics may be up to 75 percent lighter based upon specific gravity.
In-direct benefits include:
- Fuel efficiency.
- Decreased emissions.
- Decreased noise and vibration levels.
- Lower overall weight of the product.
- Logistics/freight advantages.
- Ability to produce complex shapes and designs without secondary assembly steps. These same shapes manufactured in metal are expensive and may require ancillary stamping and tooling.
- Ability to form logos and warning labels as well as other branding directly into the part.
- Mating points easily designed in the part.
- Multiple finishes on the same part.
- Part Consolidation.
Indirect benefits include:
- Decreased cost.
- Decreased assembly time.
- Decreased part numbers, carrying costs and inventory.
- Increased aesthetics.
- Part consistencies and repeatability from part-to-part as well as lot-to-lot.
- There are many thermoforming resins available – HIPS, ABS, PC, PE, TPO, acrylic and alloys – the correct material is matched to achieve the clients’ needed requirements and pricing.
- Materials meet flame, smoke and toxicity requirements that are required by the transit industry.
- Monolithic color eliminates painting.
- Texture availability without cost implications on sheet.
- Texture tooling for specific texture requirements.
- No corrosion.
General Plastics, Inc. is your full-service thermoforming solution with more than 30 years of experience with expertise in the following applications:
- Pressure forming (6’ x 10’)
- Vacuum forming (6’ x 10’)
- CNC & Robotic trimming
- Full assembly and sourcing
- Packaging and kitting
- Prototype and production tooling
- DFMA assistance
- Design freedom for undercuts, texture and color
To discuss your Thermoforming needs, call General Plastics, 414-727-6855; Toll Free: (888) 611-0270 or email us firstname.lastname@example.org.