Many parts that are currently being injection molded could also be thermoformed.
Thermoforming is a preferred solution in many cases, such as when
The following table provides some points to consider.
| Injection | Thermoform | |
|---|---|---|
Ideal volume: |
1,000 and up (varies by part characteristics) | up to 10,000 (varies by part characteristics) |
Minimum lot size: |
1,000 | 10 |
Lead time: |
20 weeks and up | as little as 1 week |
Tooling costs: |
$25,000 - $100,000 | $500 and up, depending on material |
Mold construction: |
Steel - 2 (or more) parts | Various composites, aluminum, or sometimes wood - usually one part, sometimes two |
Amortization of tooling: |
over 1,000 - 100,000 parts. If sales do not meet projections, there could be a substantial loss, as tooling costs cannot be recovered | over 100 - 5,000 parts. Lower volumes needed to recover tooling investment. |
Design changes: |
steel tooling requires longer turnaround, and changes could require new tooling, at substantial cost | composite or aluminum tooling is quickly reworked, and lower tooling costs mean less financial risk |
Part size: |
Large parts can have prohibitively expensive tooling and unit costs | Ideal for large parts |
Appearance: |
Ejection marks, gate marks, porosity can be an issue | One surface of plastic is completely untouched (for one-part mold), and thus generally has no defects. Surface in contact with mold offers excellent detail, based on mold. The application will determine which is the finished side. |
For assistance in making a decision, give our sales or engineering staff a call!
