Behind every consistent thermoformed part there is a controlled process. This article walks through sheet extrusion, heating, forming, trimming and the inspection steps that matter.
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 anti-static and conductive component 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 carbon filled black grades; standard JEDEC and custom matrix layouts; cleanroom compatible versions. Materials most often specified are Polyethylene Terephthalate, Polypropylene, Polystyrene, Polycarbonate, 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, device inserts, battery packs.
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 |
|---|---|---|---|
| Polycarbonate | 1.20 g/cm³ | 55-70 MPa | -40°C to 120°C |
| Acrylonitrile Butadiene Styrene | 1.04-1.06 g/cm³ | 30-50 MPa | -20°C to 80°C |
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
Polystyrene is frequently the default selection here: HIPS is the default thermoforming sheet for food packaging and appliance liners.
Processing method drives both cost and performance, so it should be fixed early in the design.
Critical control points are melt temperature, cooling time and the inspection of the first pieces of every shift. A stable process is documented with a parameter sheet that travels with the tool.
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.
Each step below has its own control points, and skipping one of them is where most defects start.
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.
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.
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.
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.
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.
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.
If you are planning a new electronics and electrical project, send us your drawing, annual volume and target properties, and we will come back with a material proposal, a tooling plan and a budget quotation.
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