Thermoforming rewards designs that respect how a heated sheet stretches. These rules prevent most tooling rework and most thickness complaints.
This guide is written for engineers, purchasers and project managers who need a practical answer, not a resin data sheet.
This category covers a family of products rather than a single item. In practice a buyer defines thermoformed point of sale display trays by three things: the base resin, the format or dimension, and the performance or certification level it has to meet. Typical options in this category include gauge 0.50 to 2.00 mm; counter and shelf formats; stackable for transport. Materials most often specified are Polystyrene, Polyethylene Terephthalate, Polypropylene, Recycled PET, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the electronics and electrical sector the decision is usually driven by ESD protection and dimensional accuracy, with cleanliness as a secondary requirement. Typical end uses include component trays, accessory blisters, connector carriers.
These figures are typical for commercial grades and should be confirmed against the supplier's certificate for your specific lot.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Polyvinyl Chloride | 1.38-1.45 g/cm³ | 40-55 MPa | -10°C to 60°C |
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
| Polyethylene Terephthalate | 1.35-1.40 g/cm³ | 50-70 MPa | -40°C to 70°C |
Polyvinyl Chloride is frequently the default selection here: PVC can be formulated from rigid pipe compound to soft medical grade by changing plasticiser content.
Thermoforming rewards designs that respect how the sheet stretches. These rules prevent most tooling rework.
Send these rules to your designer together with the sheet gauge and the target cycle time; most tooling modifications come from ignoring draft and corner radii.
Beyond the base resin, most suppliers offer UV stabilised, food contact, flame retardant, anti-static and recycled content versions of the same product. Ask which additive package is included, because it is often the difference between a part that lasts three years and one that lasts ten.
The route below is the one most factories use for this type of part.
Secondary operations such as printing, welding, machining and assembly are often cheaper to do in the same factory, and they reduce the risk of mismatch between components.
Work through these points in order and most specification mistakes disappear.
Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.
A new tool typically takes 25 to 45 days depending on cavity count and complexity, followed by T1 samples within one week. Existing tools can usually start production within 10 to 15 days of order confirmation.
Yes. Standard samples are normally free of charge and shipped within three working days; custom samples are charged at cost and credited against the first production order.
We can provide ISO 9001 quality system documentation, material certificates, RoHS and REACH statements, and where applicable food contact, flame retardancy or drinking water approvals. Tell us your target market and we will match the document set.
Standard production tolerance follows the relevant ISO or DIN tolerance class for the process; tighter tolerances are possible after machining or grinding, but they add cost. Define the tolerance only on the functional dimensions.
Colour is controlled with a masterbatch reference approved by the customer, and every production lot is checked against the approved sample under standard lighting before shipment.
Share your specification and quantity with us and we will recommend the most cost effective material, tooling route and packing method for your market.
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