📚 Table of Contents
Thermoforming during product development
Automobiles and Transportation
Medical devices and equipment
Packaging and Display
Electrical and electronic equipment
consumer goods
Industrial equipment
Product Prototyping Case Study - Beta Design Office
Thermoforming is a widely used manufacturing process for producing a variety of products. It involves heating thermoplastic materials to a malleable state and then shaping them into the desired form. Common applications include packaging, prototyping, food and beverage containers, and small-batch production.
In this guide, we will explore some trending applications of thermoforming, divided into three categories:
As consumers, we typically only see thermoforming in the final parts used in daily life. However, thermoforming is often used throughout the product development process.
There are three main stages that can be used in thermoforming:
1. Rapid prototyping
This process is used to evaluate the functionality and design of an idea before investing in expensive production methods. Multiple iterations can be created quickly to test assembly paths, coatings, or post-processing options.
2. Tools and fixtures
Thermoforming can be used to manufacture tools for producing other products. For example, using thermoformed transparent fixtures can ensure consistent and precise production of parts.
3. Final Use Parts
Thermoformed parts are common in many industries, including automotive, medical, packaging, and electronics.
Which industries are currently using thermoforming?
Automobiles and Transportation
Thermoforming is widely used in the automotive and transportation industries to produce internal and external parts. These parts are made of materials such as ABS, which can withstand high temperatures and pressures.
• Interior components of the car : dashboard, door panels, and armrest backrests
• Automotive exterior components <br />Bumpers, spoilers, and fenders
• Recreational vehicle components <br />Motorhomes, RVs and trailers
• Aircraft components and interior <br /> Windows, seats, armrests, and control panels
• Marine Components <br />Hull, deck, canoe, kayak and interior components
• Transporting <br />seats, interior panels, lamp covers, and gap covers
ABS car parts made with Mayku Multiplier
Medical devices and equipment
Thermoforming is an ideal process for manufacturing medical devices and equipment. It can provide sterilizable, durable, lightweight, and precise parts.
• Medical device casings <br /> Hearing aids, ventilators, and defibrillators
• Medical Equipment <br />Hospital bed components, waste bins, containers, and sterile packaging
• Orthopedics and Prosthetics <br />Custom-made braces, splints, and orthotics
Medical packaging prototype made using a Mayku Multiplier compression molding machine (Source: Oertli)
Packaging and Display
Thermoforming is widely used in the packaging and display industries. These parts are typically made of materials such as PETG , HIPS , and PVC, offering transparency and excellent impact resistance.
• Food and beverage packaging <br />Spiral and blister packs, plastic pallets
• Point-of-sale display <br />Product display rack
• Logos <br />Logos used both inside and outside the office
PETG packaging made with Mayku Multiplier
Electrical and electronic equipment
Thermoforming is an ideal solution for producing electrical and electronic components. It provides lightweight, strong, and heat-resistant parts with precision and consistency.
• Computer enclosures <br />Desktop and laptop computers, switch boxes, control panels, and junction boxes
• Protective case <br /> Laptops, measuring equipment, and cameras
• Refrigeration components <br />Door panels and lining
Computer mouse prototype made using
consumer goods
Thermoforming is a cost-effective method for producing consumer goods with fine details and tight tolerances. It is an ideal solution for manufacturers that need to meet high standards.
• Toys <br />Remote control cars, building blocks, puzzles, and action figures
• Sports Equipment <br />Helmets, protective gear, and fitness equipment
• Furniture components <br />Armrests, backrests, and base components
Industrial equipment
Thermoforming is widely used in many industries and is a key method for prototyping and manufacturing specific applications.
• Agricultural equipment <br />panels, internal machine parts, sprayer housings, and feed containers
• Acoustic components <br />Sound insulation and insulation
• Lighting <br>Lampshade
Thermoformed lampshade prototype
Beta collaborated with Mayku to design a range of consumer accessories, which were prototyped using Multiplier to showcase various possibilities to designers and manufacturers.
Beta designed three consumer electronics products— a mechanical keyboard case , a mouse , and a webcam —to demonstrate just how refined and detailed Multiplier's components can be. These products are designed for the "user," with customizable cases that can be quickly replaced and replicated to test different textures and finishes.
Free and unrestricted prototype creation
Beta uses a combination of 3D printing and pressure molding dies for product prototyping. Each die takes less than five minutes to make and is ready to use immediately. The Multiplier can capture fine surface details, making it an excellent tool for experimenting with textures in dies.
Color, material, surface treatment
Beta uses different CMF (color, material, finish) effects to highlight the Multiplier's capabilities for makers and designers.
You can immediately test a fast, affordable 2mm mold on the same machine, and then proceed with a flexible mold or choose a sheet of 5mm or more to create an injection mold quality shell.
Shorten delivery cycle
Outsourcing custom mold design or prototype parts can be a lengthy process. It can involve going back and forth on design drafts and then waiting up to 12 weeks for the mold or part to be ready.
However, using high-speed benchtop thermoforming can transform an idea into a completed mold or part within 48 hours . Shorter delivery cycles increase a company's sales potential and productivity .
In this era where product appearance is paramount, simply changing your production model can not only allow you to create more creative and artistic designs, but also free you from the time and financial constraints of outsourcing mold manufacturers, giving your business a significant head start!
►Learn more about thermoforming technology? Please see our Mayku guide:
[Thermoforming Applications] Vacuum Forming vs. Pressure Forming: What's the Difference? We'll Tell You All About It
[3D Printing Knowledge] Application Guide for Creating Thermoforming Templates in FDM 3D Printing
[3D Printing Knowledge] Application Guide to Creating Thermoforming Templates using SLA 3D Printing
[3D Printing Knowledge] Application Guide to Creating Thermoforming Templates with SLS 3D Printing
►Learn more about Mayku benchtop thermoforming equipment
• Mayku Mutiplier Compression Molding Machine
• FormBox desktop vacuum forming machine
References Reference 2