Specification sheets for twin sheet thermoformed products are full of abbreviations. This guide translates sheet gauge, cavity layout and trim tolerance into decisions you can make.
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 twin sheet thermoformed products 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 hollow double wall structures; large panels over 2000 mm; integrated mounting bosses. Materials most often specified are PC/ABS Alloy, High Density Polyethylene, Acrylonitrile Butadiene Styrene, Polypropylene, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the automotive and mobility sector the decision is usually driven by dimensional stability and heat resistance, with impact strength as a secondary requirement. Typical end uses include commercial vehicle trim, interior panels, line side trays.
The table below summarises the values that usually decide the material choice.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Acrylonitrile Butadiene Styrene | 1.04-1.06 g/cm³ | 30-50 MPa | -20°C to 80°C |
| High Density Polyethylene | 0.94-0.97 g/cm³ | 20-32 MPa | -50°C to 80°C |
| PC/ABS Alloy | 1.13-1.15 g/cm³ | 45-60 MPa | -30°C to 110°C |
High Density Polyethylene is frequently the default selection here: HDPE combines toughness with chemical inertness, which is why it dominates pipe and tank markets.
The table below summarises the values that usually decide the material choice.
When you read a supplier quotation, check that the dimension, the resin grade, the colour reference and the tolerance class are all stated. A quotation that only gives a price per piece is not comparable between suppliers.
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.
These are the criteria that actually predict whether the part will perform in service.
Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.
Standard packing is export cartons on fumigation-free pallets, with custom labelling, barcode and retail packing available. We also handle consolidated containers and door to door delivery.
For standard sizes and colours the minimum is usually one pallet or one production run; for custom tooling the economic minimum depends on the tooling cost amortised over the expected volume. Send us your annual volume and we will calculate the break even point.
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.
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.
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.
Our team supplies twin sheet thermoformed products to automotive and mobility customers worldwide, with samples, material certificates and full inspection reports available before mass production.
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