Thermo Forming Service

Plastic Injection Manufacturer with Customized Service For Many Industries - Mulan Group Contact@china-plasticparts.com +86 021 3479 1660

Thermoforming Service in Mulan Group

Mulan Group is your strategic partner for high-quality, cost-effective custom plastic thermoforming and OEM/ODM services. We excel at providing efficient, rapid production with high output and short lead times, ensuring your time to market is accelerated. Our processes emphasize optimized material use to minimize waste and reduce costs, while our commitment to low-energy manufacturing and rigorous quality control guarantees durable, consistent, and environmentally friendly products. Choose Mulan Group to bring your designs to life in a reliable and precise way.

What is Thermoforming

Thermoforming is a secondary molding technology that uses thermoplastic sheets as raw materials. After softening by heating, the sheets are then pressed against a mold surface using vacuum, air pressure, or mechanical pressure. The product is then cooled and shaped to obtain the final product. This process is highly adaptable, has low equipment and mold costs, and produces high-quality products. Typical applications include fast food containers, bathtubs, and automotive interior parts.

Main Types of Thermoforming Processes and Their Advantages

Vacuum Forming

our Preferred Low-Cost, High-Efficiency Solution

▪ Description: The most basic and common type. A heated and softened plastic sheet is tightly covered onto a mold. A vacuum is created to generate negative pressure, causing the sheet to adhere to the mold surface and form the shape.

▪ Characteristics: The mold usually has only one side (male or female mold).

Ultimate Economy

Molds primarily utilize aluminum or resin molds, resulting in significantly lower mold-making costs and lead times compared to injection molding. This greatly reduces the barriers to entry and investment risk for your project, making it particularly suitable for new product development and validation or small-to-medium batch production.

Unparalleled Large-Size Production Capacity

We can economically produce extra-large housing parts (such as machinery covers and billboards), which is difficult or extremely costly to achieve with many other processes.

Rapid Response and Delivery

Simple mold structure and fast manufacturing speed. From drawings to samples, we offer industry-leading delivery speed, helping you quickly seize market opportunities.

Pneumatic Forming/Air Compression Forming

Designed for Higher Product Value

▪ Description: Uses compressed air (positive pressure) as power to quickly and forcefully press a heated and softened plastic sheet against the mold surface.

▪ Characteristics: Usually requires matching male and female molds; higher pressure and more precise control.

Superior Details and Texture

Through high-pressure air forming, details such as textures and logos from the mold can be perfectly replicated on the product surface, easily achieving high-gloss, matte, and other premium textures, significantly enhancing the product's grade.

Superior Structural Strength and Uniform Wall Thickness

Compared to vacuum forming, we can better control material distribution, producing parts with more uniform wall thickness and a more robust structure. This is crucial for functional components with strength requirements and the ability to withstand loads.

Conquering Complex Geometry

With higher forming pressure, we can help you achieve challenging designs such as deeper stretching, undercuts, and complex curved surfaces, expanding your design freedom.

Compression Molding

The Ultimate Answer to Complex 3D Structures and Ultra-High Precision

▪ Description: Primarily relies on mechanical pressure to form a heated and softened sheet between a closed male and female mold.

▪ Characteristics: Similar to stamping, it can form very complex parts.

Unparalleled Dimensional and Structural Accuracy

Through the precise fit of male and female molds, we can provide you with products that offer the highest dimensional stability and the most accurate structural details, perfectly matching your assembly needs.

Achieving Truly Complex 3D Designs

This process can produce extremely complex three-dimensional structures that are impossible to achieve with other thermoforming methods, such as reinforcing ribs, snap-fits, and embedded structures, helping you achieve highly integrated product designs.

Industries We Serve for Thermoforming Custom Plastics

As a manufacturer, our core advantages lie in: mold investment being significantly lower than injection molding, making it particularly suitable for large-size, small-to-medium batch products; short production cycles and rapid delivery; and strong design and material selection capabilities, enabling us to provide cost-effective solutions tailored to specific customer needs. To date, we have provided thermoformed parts production and processing for customers in the following industries, and many more have chosen us as a long-term supplier.

Automotive

Interior panels, dashboards, seat back panels, battery pack housings. Features: Low mold cost, easy lightweight design, efficient production of large interior parts, strong surface texture processing capabilities.

Construction

Sound insulation panels, skylights, decorative moldings. Features: Capable of producing large-size, curved components, good weather resistance, high production efficiency, and significant overall cost advantages.

Agricultural Equipment

Tractor mudguards, harvester panels, agricultural machinery cab interior trim. Features: Excellent impact resistance, corrosion resistance, suitable for small-to-medium batch customization, robust and durable components.

Furniture

Table and chair backs, cabinet doors, bathroom vanity panels. Features: High design freedom, enabling complex three-dimensional shapes and surface coatings, balancing aesthetics and durability.

Material Handling

Pallets, turnover boxes, cargo hold linings. Features: One-piece molding, robust structure, high edge strength, impact resistance, wear resistance, and long service life.

Medical

Equipment housings, medical device trays, hospital bed slats. Features: Controllable cleanliness of the production environment (cleanroom), materials meeting medical standards, achieving antibacterial and chemical-resistant properties.

Refrigeration

Refrigerator and freezer liners and door linings. Features: Seamless liner design effectively prevents cold air leakage; mature and efficient production process; smooth surface for easy cleaning.

Transportation

Aircraft interior panels, high-speed rail luggage racks, freight car fairings. Features: Extremely lightweight to reduce energy consumption; high strength-to-weight ratio; capable of manufacturing large, streamlined components.

Telecommunications

Outdoor enclosures, equipment housings. Features: Excellent weather and UV resistance, protects internal equipment, flexible structural design for quick mold making and production.

Water Treatment and Filtration Equipment

Filter housings, filter discs, water tanks. Features: Excellent chemical resistance, can be molded into complex fluid channels, good sealing performance, and long service life.

Most Commonly Materials Used in Thermoforming

PVC/Acrylic

This material finds extensive use, particularly in micro-processor-based equipment housings. The inherent strength of PVC/Acrylic and its ability to meet stringent UL flammability standards adds to its appeal. Moreover, its adaptability extends to aesthetics, too; it can be crafted in many colours and textures to meet specific design demands.

PS (Polystyrene)

Polystyrene, or poly-phenylethene, is a thermoplastic polymer renowned for its electrically insulating properties. As a thermoplastic, it softens upon heating and can be reshaped, offering reusability. Its chemical resistance to acids and bases makes it a versatile material in various applications, including protective packaging and insulation.

PET (Polyethylene Terephthalate)

PET is a staple in thermoformed packaging, synthetic fibres, and bottle production. Known for its strength and durability, PET requires drying post-moulding, a crucial step to ensure stability and maintain shape. Its widespread use in food and beverage containers highlights its safety and reliability.

PP (Polypropylene)

Polypropylene (PP) is renowned for its fatigue resistance and thermal stability, making it essential in automotive parts, consumer goods, and living hinges. Its unique ability to withstand continuous bending without breaking is a key property. Additionally, its resistance to moisture, acids, and solvents makes PP ideal for containers and piping, as well as in medical and laboratory equipment.

LDPE (Low-Density Polyethylene)

LDPE, characterized by its flexibility and resilience, is a cornerstone in creating products that demand a balance of pliability and strength. Its resistance to moisture and chemicals makes it ideal for food packaging and laboratory containers. Additionally, its low-temperature resistance ensures reliable performance in applications ranging from frozen food packaging to flexible tubing and agricultural films.

HDPE (High-Density Polyethylene)

HDPE, known for its robustness, is integral in manufacturing durable goods like hard hats and corrosion-resistant piping. Its environmental resilience, coupled with a high strength-to-density ratio, makes it ideal for high-demand applications, ensuring longevity and reliability in products ranging from outdoor furniture to storage containers.

PC (Polycarbonate)

Polycarbonate (PC) stands out for its impact resistance and optical clarity, making it a prime choice for safety equipment, like bulletproof glass, and in automotive components. Its versatility extends to electronic media, like DVDs and Blu-ray discs, demonstrating its ability to maintain transparency and durability under stress.

PMMA (Polymethyl Methacrylate)

PMMA, famed for its glass-like clarity and UV resistance, is widely used in optical lenses, aquariums, and architectural features. Its excellent light transmission and weather resistance make it a preferred choice for outdoor applications, showcasing its ability to retain clarity and strength in diverse environments.

ABS (Acrylonitrile Butadiene Styrene)

ABS encompasses a broad spectrum of resins, making it versatile across numerous applications. It is robust and durable and can also be formulated to align with UL flammability standards. This adaptability makes ABS a favourite for various industries.

Custom Thermoforming Process: From Concept to Completion

From concept to finished product, we provide a comprehensive custom thermoforming solution, ensuring excellence in quality, efficiency, and cost-effectiveness at every stage.

01. Design & Engineering

The process begins with your concept. Our engineering team collaborates closely with you to conduct a feasibility analysis based on your ideas, 2D drawings, or 3D models. Using advanced CAD software, we refine the design, optimizing the product structure for the thermoforming process. Key considerations at this stage include material stretch ratios, draft angles, undercuts, and trim lines, resulting in final design drawings ready for prototyping and mold fabrication.

02. Prototyping & Validation

Prototyping is crucial before committing to production tooling. We typically employ CNC machining or 3D printing to rapidly create product prototypes. This step allows for:

Form & Fit Verification: Physically validating the product's shape, dimensions, and assembly.

Functional Testing: Ensuring the prototype performs as intended in its design environment.

This validation helps identify and rectify potential issues early, saving significant time and cost downstream.

03. Tooling Manufacturing

Once the design is finalized, we proceed to tooling. Based on production volume, precision requirements, and budget, we provide the most suitable mold solution:

Prototype Molds: Often aluminum, used for low-volume pilot runs and final validation.

Production Molds: Made from high-strength steel, ensuring high precision and durability for long-term, high-volume production runs.

All completed molds undergo rigorous quality inspection to guarantee they meet design specifications.

04. Thermoforming Production

The core manufacturing takes place on large thermoforming machines, involving key steps:

Sheet Heating: Plastic sheets (from rolls or cut sheets) are uniformly heated to their specific softening temperature in an oven.

Vacuum/Pressure Forming: The heated, pliable sheet is transferred onto the mold. Vacuum (vacuum forming) or positive air pressure (pressure forming) is applied, forcing the material to conform precisely to the mold cavity.

Cooling & Demolding: The formed part is cooled and solidified within the mold before being ejected via an automated system.

05. Post-Processing & Assembly

Formed parts often require secondary operations, which may include:

Trimming: Precision removal of excess material using CNC routers, routing dies, or robotic trimming systems.

Secondary Operations: Processes such as drilling, milling, screen printing, painting, or inserting metal components.

Quality Inspection & Packaging: Finished goods undergo thorough inspection (full or sampled) to ensure they meet all quality specifications before being carefully packaged for shipment.

Why Choose Mulan Group for Custom Plastic Thermoforming

Professional

We possess professional thermoforming machines (vacuum, pneumatic, and laminating), and professional mold design and manufacturing capabilities, enabling us to complete sampling in 3-4 days.

Reliable

We hold complete industry certifications, including ISO 9001, IATF 16949, ISO 13485, and UL certifications. From raw material inspection upon arrival, to initial/inspection during production, and final inspection of finished products, we have comprehensive documentation and records, enabling full traceability from raw material batches to finished products, giving you peace of mind.

Efficient

From inquiry, sampling, production to shipment, dedicated personnel handle each step, ensuring a clear and transparent process. We also have flexible production lines, allowing for rapid switching between different product lines, ensuring on-time and sufficient order delivery. Furthermore, with customers in over 30 countries, we can easily handle transportation and customs clearance issues.

Cases Display

ABS vacuum forming parts

PMMA vacuum forming parts

PP thermoformed parts

PP vacuum forming parts

Battery casing molding

Vacuum-formed automotive parts

thermoformed parts

Molded housing

Molded parts

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Looking for a reliable, quick-turn plastic molding factory of custom plastic parts? With hundreds of processing machineries, our unmatched in-house capacity ensures your parts are shipped on-time, every single time. At Mulan Group, our AS9100-certified facilities are designed for both rapid prototyping and low-volume production of end-use components.

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