Twin Sheet Forming

Twin Sheet Forming, Custom Twin Sheet Plastic Thermoforming

Twin sheet formed part manufactured using twin sheet thermormingProductive Plastics is a leading twin sheet formed plastics manufacturing for a variety of industries. Productive Plastics goes beyond being simply a twin sheet thermoforming contract manufacturer, providing manufacturing engineering and product design assistance based in technical expertise and many years of plastics experience. Productive Plastics is ISO 9001:2008 registered.

Typical Applications for Twin Sheet Forming

Twin sheet thermoformed parts can have formed features and exhibit high strength and stiffness with low weight. Productive Plastics currently uses twin sheet forming to make industrial component parts such as enclosure panels for medical, printing and electronic equipment, and exterior parts in heavy truck and bus applications. Other items that are thermoformed using the twin sheet forming process are air ducts, truck bed liners, portable toilets, carrying cases, double-walled floors, fuel tanks, electrical enclosures, vending machine chutes, ATV parts, pallets and other transportation applications.

Why Use Twin Sheet Forming?

Twin sheet thermoforming has advantages over other methods of thermoforming and other plastics manufacturing processes depending on the part and its use. This is where Productive Plastics engineers and technicians excel at providing expert guidance in selecting twin sheet forming where appropriate.

Here are some potential advantages that would make twin sheet forming a good choice for your plastic part:

  • Has a lower tooling cost – about 20-30% less than blow molding
  • Yields parts with high structural integrity and rigidity compared to single walled thermoforming
  • Allows for an enclosed cavity
  • Can include various internal reinforcements, including structural elements and rigid foam components
  • Can have molded-in attachments and other features

Twin Sheet Forming Technology

Twin sheet thermoforming is a technically challenging process that uses two plastic sheets to make hollow or double-walled 3-dimensional parts. There is a separate mold for the top platen and for the bottom platen. The two plastic sheets are heated. To create the hollow part, pressure or vacuum is used to move the two sheets against the top and bottom mold, while the molds move together to join the two sheets at the edges as dictated by the mold. The result is a hollow part with detailed, precise exterior surfaces and strongly welded edges.

Materials Used in Twin Sheet Thermoforming

  • HDPE – Cost effective material for industrial applications requiring high impact strength
  • ABS – Broad spectrum of resins used across a number of applications, can be formulated to meet UL flammability standards
  • TPO – High impact material delivering performance in cold and high heat applications
  • PC/ABS – Alloy delivers UL approval in addition to high impact performance
  • HIPS – Low cost resin used in many POP applications requiring excellent forming characteristics
  • PVC/Acrylic – Widely used resin in micro-processor based equipment housings, meets most stringent UL standards for flammability and can be made in wide range of colors and textures

Productive Plastics’ Twin Sheet Forming Capabilities

Productive Plastics offers a good range of technical capabilities based on the equipment used, materials used, and desired product properties.

Equipment – Productive Plastics is committed to using first-rate equipment, including the following machines:

  • 48″ x 72″ four station rotary twin sheet former
  • 60″ x 72″ single station twin sheet former
  • 48″ x 96″ single station twin sheet former

All machines are capable of vacuum, pressure and twin-sheet forming.

Terminology Note

Productive Plastics and the plastics industry typically use the terms “twin sheet forming” and “twin sheet thermoforming” interchangeably.

Contact Productive Plastics for Twin Sheet Thermoforming

Please Contact Productive Plastics, one of the most innovative thermoforming companies, for assistance or to get a quote for twin sheet forming.

Request a free Heavy Gauge Plastic Thermoforming Process and Design Guide from Productive Plastics.