1/21/2017 FAQs,PlasticThermoforming,VacuumForming,&RotationalMoldingFiberPad,Inc.

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CompanyProfile FrequentlyAskedQuestions
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1.Whatisthermoforming?
Testimonials 2.Whatarethebenefitsofthermoforming?
3.Whatisvacuumforming?
Links 4.Whatisthedifferencebetweenthermoformingandvacuumforming?
FAQs 5.Whattypeofplasticscanyouthermoform?
6.Whenandwheredoesplasticformingfit?
ContactUs 7.Whatkindofcosmeticfeaturescanbeachievedwiththermoforming?
8.WhatkindofformingandtrimtolerancescanFiberPad,Inc.holdformyparts?
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9.HowthickofmaterialsdoesFiberPad,Inc.workwith?
10.Whattypesoftoolingareusedinthermoforming?
a.MachinedAluminumMolds
Fiber Pad ... b.CastAluminumMolds
c.Composite/TemporaryMolds
i.Whataremaleandfemalemolds?
11.Whatothertoolingisrequiredinthethermoformingprocess?
12.Whatisleanmanufacturing?
13.Whatisthetypicalleadtimeforaproject?
14.Whatarethetypicalstagesofaprojectfromconcepttocompletion?
15.WhyshouldIchooseFiberPad,Inc.formyplasticformingneeds?
FiberPadManufacturing 16.HowdoIgetafreequote?
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1.Whatisthermoforming?

Thermoformingisagenerictermusedtodescribeagroupofprocessestoproduceplasticpartsfromaflatsheetof
plastic under temperature and pressure. A plastic sheet is heated to a pliable forming temperature, formed to a
specificshapeinamold,andtrimmedtocreateausableproduct.Thetrimmedmaterialisregroundandrecycled.

Ifyouareunfamiliarwiththermoformingyouwouldbegreatlysurprisedtofindouthowmanythermoformedproducts
youcomeacrossindailylife.Thermoformingdiffersfrominjectionmolding,blowmolding,rotationalmolding,aswell
asotherformsofprocessingplastics.

Contactustoseeifyourpartcanbethermoformed.

2.Whatarethebenefitsofthermoforming?

Thermoforminghasseveraladvantagesoverotherprocesses.Thermoformingisefficientandverycosteffectivefor
theproductionofmanyplasticpartsdependingonsize,shape,andquantity.Unlikeotherprocesses,thermoforming
hasamuchshorterleadtime,initialprojectcostsareusuallymuchlower,thereisalargefreedomofdesign,small
detailscanbeadded,precoloredplasticisavailablewithextensivechoiceofpatterns,textures,andfinishes,and
providesanexcellentpartvolume/qualityratio.

3.Whatisvacuumforming?

Vacuum forming is a process in which a thermoplastic sheet is heated to the appropriate temperature, stretched
aroundorintoamold/pattern,andconformedtothemoldbyapplyingvacuumpressurebetweenthemoldsurface
and the plastic sheet. Because heating of the material to be formed is required, vacuum forming is considered a
thermoformingprocess.

4.Whatisthedifferencebetweenthermoformingandvacuumforming?

Vacuumformingisatypeofthermoformingbothprocessesrequireheatingplastictoamalleabletemperatureand
thencoolingtheplasticintoanewform.Vacuumformingisanadditionalprocessduringthermoforminginwhich
vacuumpressureisusedtoconformplastictothemoldduringforming.

5.Whattypeofplasticscanyouthermoform?

Plastics that lend themselves best to thermoforming are: acrylonitrilebutadienestyrene copolymer (ABS), high
impact polystyrene (HIPS), high density polyethylene (HDPE), high molecular weight polyethylene (HMWPE),
polypropylene (PP), polyvinyl chloride (PVC), polymethyl methacrylate (or "acrylic") (PMMA), and polyethylene
terephthalatemodifiedwithCHDM(PETG).Fiber Pad, Inc. will match custom colors and custom textures and will
specifyotherrequirementssuchasFDAapprovedmedicalandfoodmaterial,electrostaticdischargematerial,and
fireretardentmaterial.

Askusaboutourexperiencewithvarioustypesofplasticresins.

6.Whenandwheredoesplasticformingfit?

Large panels, housings, enclosures, and similar parts are especially wellsuited to the thermoforming process.
Tooling costs for these parts is considerably less than injection molding, which may have costprohibitive tooling
costs.Partswithfeaturesmostlyconfinedtoonesideofthepartarebestsuitedtothermoforming,butfeaturesonthe
uncontrolledsideofthepartmaybeaddressedbytrimmingorfabricationandassembly.

7.Whatkindofcosmeticfeaturescanbeachievedwiththermoforming?

Sharp,crispdetailwithclosetolerancescanbeachieved.Undercuts,formedintexture,formedinlogos,formedin
hardware,andcustomcolorsarejustafewofthemanyfeaturesthatcanbeaccomplishedwiththermoforming.This
subjectiscoveredinmoredetailonourdesignparameterspage.

8.WhatkindofformingandtrimtolerancescanFiberPad,Inc.holdformyparts?

Thefollowingtablelistsourstandardtolerances:

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1/21/2017 FAQs,PlasticThermoforming,VacuumForming,&RotationalMoldingFiberPad,Inc.
YoucanalsodownloadaPDFformofourDesignGuide
Distance PressureForming VacuumForming
Lessthan6" .015" .020"
6"to12" .020" .025"
12"to18" .025" .030"
Above18",add .002"perinch .002"perinch
ExcludesPolyethylene

CNCTrimmedFeatures:

Machinedfeaturesfromaformedsurface.030"
"Cuttocut".020"
HoleDiameter.010"<2"

9.HowthickofmaterialsdoesFiberPad,Inc.workwith?

Wetypicallydealwithmaterialsranginginthicknessfrom.015"to.500".

10.Whattypesoftoolingareusedinthermoforming?

Threetypesoftoolingarecommonlyused:

a)MachinedAluminumMolds

MachinedaluminummoldsareusuallydoneonCNCmachinesfromgeneratedCADfilesandcanbe
either male or female. Typically built for shallow parts with small draw ratios they hold very close
tolerancesandcanbemountedontemperaturecontrolbasesandusedwithorwithoutplugassist
molds.

b)CastAluminumMolds

Cast aluminum molds are cast at a foundry from a pattern machined by Fiber Pad, Inc. from a
composite material. The temperature controls are cast into the back and sides of the molds at the
foundry.Castaluminummoldstypicallyarebuiltforpartswithlargedrawratiosandmaybemaleor
femaleandvacuumformorpressureform.Featuressuchastexture,looseandpneumaticcores,and
insertsareavailable.

c)Composite/TemporaryMolds

For prototyping and short production runs, costefficient composite materials are used for mold
construction.Thesemoldsproducepartsthataretobeevaluatedforfit,form,andfunctionandmaybe
modifiedtoevaluatepossibledesignchanges.Thesemoldsareforvacuumformingonlyandarenot
temperaturecontrolled.Thesemoldshavealimitedlife.

i)Whataremaleandfemalemolds?

Male and female molds are the only two fundamental types of forms, but they yield
significantlydifferentfinishedparts.Theleasttimeconsumingandcheapestmethodis
themaleorpositivemold.Thisisaformthatmimicsthefinalshapeofthepart,butthe
partisfabricatedoveritsoutersurface.Malemoldsshouldbeusedwhenfewerthan5
10partsarebeingproduced.Largerrunsusuallywarrantthetimeandcostoffemale
molds.

Femaleorcavitymoldsaregenerallymorecostly,buttheyoffernumerousadvantages
for medium to large production runs. Finishing time is significantly reduced because
everypartemergeswithasmoothoutersurface.Femalemoldsalsolendthemselves
tousewithcorematerialsbecausetheouterskinisalwaysasmoothregardlessofhow
inconsistentlythecoreisusedinsidethepart.

11.Whatothertoolingisrequiredinthethermoformingprocess?

AvacuumfixtureisrequiredwhenapartmustbeCNCtrimmed.Vacuumfixturesareconstructedbytakingareverse
impressionofthepartandmountingthisimpressionintoavacuumbox.Thetrimfixturethenholds,undervacuum
pressure, each part being CNC trimmed to ensure consistent results. Other tooling specifically required in the
forming,trimming,fabrication,andassemblyofeachpartisdesignedbyFiberPad,Inc.engineersandconstructed
bytheFiberPad,Inc.toolingdepartment.

12.Whatisleanmanufacturing?

An overall methodology that seeks to minimize the resources required for production by eliminating waste (non
value added activities) that inflate costs, lead times and inventory requirements, while emphasizing the use of
preventivemaintenance,qualityimprovementprograms,flexibleworkforces,andproductionfacilities.

Takealookatwhatwedotoimplementleanmanufacturing.

13.Whatisthetypicalleadtimeforaproject?

FiberPad,Inc.worksefficientlytogetyourperfectproductoutthedoorquickly.Atypicalprojectcantakeanywhere
between410weekstostartproduction.However,leadtimescanvarybasedonthecomplexityoftheprojects,the
leadtimeofrawmaterials,andtheneedsandrequirementsofeachcustomer.Someextensiveprojectshavetaken
monthstogettofinalproductionwhileourregularcustomerscanenjoyoneweekturnaroundonanorder.Thebest
waytodeterminewhatyourleadtimewillbeistocontactusregardingyourproject.

14.Whatarethetypicalstagesofaprojectfromconcepttocompletion?

Thetypicalstepstoaprojectareasfollows:

Design Stage: The customer supplies their own design and Fiber Pad, Inc. generates 3D presentations for their
approval.Onceaconceptisapproved,moldengineeringdrawingsaregenerated.

Prototyping Stage: If required by customer, a prototype mold is generated and samples of the parts are made to
judgefit,form,andfunctionandtodetermineapplicableplasticmaterialandcolor.R&Disdoneatthisstage.

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1/21/2017 FAQs,PlasticThermoforming,VacuumForming,&RotationalMoldingFiberPad,Inc.
FinalToolingStageandmaterialordering:Precisionaluminumtoolingandallformingandtrimfixturesaremade
andmaterialisorderedbasedonthesizeofthetooling.

Production:Uponarrivalofcustomextrudedmaterial,productioncommences.Firsttimeproductionrunsusuallytake
alongertimethenrerunssinceittakestimetoregisteranddocumentthemachineandthesetupprocedure.

Shipping:Productsareshippedeitherinonelotorwarehousedforlotreleasesasestablishedbycustomers.

15.WhyshouldIchooseFiberPad,Inc.formyplasticformingneeds?

FiberPad,Inc.hasbeenexceedingcustomerexpectationsforover30years.Wehavetheexperience,expertise,
andtechnologynecessarytobringyourcustomthermoformedpartintoreality.Weprideourselvesonproductquality
andcanprovideyourturnkeypartwithminimalleadtime.AllofthesereasonsmakeFiberPad,Inc.anexcellent
choice for your thermoforming provider. We are your best choice because the people of Fiber Pad, Inc. have the
desiretoprovideyouwithexceptionalcustomerservice.

16.HowdoIgetafreequote?

Youalreadyhaveyourproductdesigned.YouprobablyhaveitasadrawingorCADandknowthedimensionsand
materialthatyouwanttouse.Wearehappytoprovideyouwithafreequote!Justclickhere.

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