Manufacturing: Thermoforming versus Injection Molding

The 2nd Reason Products Don't Make It To Market - Manufacturing Demons

According to the United States Census Bureau, "New orders for manufactured goods in November [2006]- up two of the last three months-increased $3.4 billion, or 0.9 percent, to $394.3 billion."

But how many of those dollars have been wasted due to problems during the development and manufacturing phase? In order for manufacturing to go smoothly, "big" decisions need to be made up front about things like tooling, materials and pressure forming vs. thermoforming.

Challenge
You're still not sure that thermoforming is the best option; you're still considering injection molding.

Strategy
It's important that you're comfortable in your decision, whichever direction it goes. There are, however, many distinct economic and practical benefits to using thermoforming over injection molding, including its flexibility in tooling and engineering and its fast set-up and production of custom plastic enclosures.

Advantages of Thermoforming compared to Injection Molding

Short lead time
Speedy tooling build cycle
Ideal for small batch production
Extensive choice of patterns, finishes and textures
Ability to produce thin-walled parts
Excellent part volume/quality ratio
Ability to form large parts (48" x 96")

Challenge
You're still unsure of the right materials to use for your plastic enclosures.

Strategy
Here are some points to consider:

What's the application? Outside applications will need different capabilities-such as UV stability and temperature resistance-than inside applications.
Are you considering polycarbonates? If yes, keep in mind that polycarbonates can be difficult to thermoform and injection mold due to the material properties. ThermoFab has the manufacturing equipment to handle these tricky materials.
The materials used for injection molding can be used for thermoforming, but it doesn't work the other way around. More options exist with thermoforming.

Challenge
Tooling seems like a complicated process-how can you make sure everything runs smoothly?

Strategy
Tooling is important. And it can complicate manufacturing if poor decisions are made. Make sure your thermoforming company closely monitors the tooling process. For example, ThermoFab maintains maximum control over the entire tooling process to eliminate the risks of timeline mishaps, misinterpretation of your concept, and other potentially expensive problems.

Successful Tooling Requires

A skilled craftsperson who considers the plastic, shrink and aluminum tooling necessary to create the desired parts from your 3D files.
A talented team of engineers and designers to move the project along seamlessly and with precision and to keep everyone on track for a quality outcome.
Thorough inspection of every tool by a demanding team of tooling and engineering professionals.
The ability to make necessary changes and refinements quickly so your project stays on deadline and your product performs as intended.

Tooling Pitfalls to Avoid

Wooden tools
Cast tools (alloy shrinkage during solidification causes dimensional errors)
Creating tooling without 3D files
Poor Fit
Lack of documentation
Lack of standards-paint, texture and gloss

For More Tips on Getting Your Product To Market Read Our Tips Guide: 3 Reasons Why Some of the Best Ideas Never Make It To Market