If you specify Polystyrene (PS / HIPS) for thermoformed packaging inserts and dividers, a handful of properties decide whether the part survives forming and service. These are the values worth checking on every data sheet.
The notes below come from day to day production and export work with overseas buyers.
This category covers a family of products rather than a single item. In practice a buyer defines thermoformed packaging inserts and dividers 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 anti-static grades; custom footprints to fit outer cartons; 2 to 48 cavity layouts. Materials most often specified are Polyethylene Terephthalate, Polystyrene, Polylactic Acid, Recycled PET, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the toys and games sector the decision is usually driven by child safety and presentation, with durability as a secondary requirement. Typical end uses include game inserts, action figure blisters, collector windows.
Typical values for a general purpose grade are listed below; filled, stabilised and speciality compounds will differ.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
| Polylactic Acid | 1.24 g/cm³ | 50-60 MPa | up to 55°C (HDT) |
| Polystyrene | 1.04-1.06 g/cm³ | 30-50 MPa | -20°C to 70°C |
Polystyrene is frequently the default selection here: HIPS is the default thermoforming sheet for food packaging and appliance liners.
The table below summarises the values that usually decide the material choice.
Density 1.04-1.06 g/cm³, tensile strength 30-50 MPa, continuous service temperature -20°C to 70°C and melt range 180-240°C are the four values to circle on the data sheet. Everything else is secondary for most toys and games projects.
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.
Processing method drives both cost and performance, so it should be fixed early in the design.
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.
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.
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.
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.
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.
Our team supplies thermoformed packaging inserts and dividers to toys and games customers worldwide, with samples, material certificates and full inspection reports available before mass production.
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