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Productive Plastics Welcomes Norman Vaughn as VP of Quality and Compliance 

I am pleased to announce the addition of Norman Vaughn as VP of Quality and Compliance to the Productive Plastics team.

For decades Norman has been helping dozens of manufacturing and service companies improve quality, productivity, and operational excellence in a wide variety of industries. Norman served as the Senior Director of Quality at CARDONE Industries in the Automotive Aftermarket, and most recently as Executive Director of DoV Operational Excellence Solutions.

After completing engineering courses at Temple University, Penn State Great Valley, and the University of Wisconsin, Norman received his BA in Organizational Management from Eastern University and has been recognized by the American Society for Quality (ASQ) as a Certified Quality Engineer and Certified Manager of Quality/Organizational Excellence.

Norman will be working closely with myself and the rest of the Productive Plastics team to bring you the highest level of service and quality thermoforming manufacturing in the industry.

Regards,

Evan Gilham

President | Productive Plastics


Norman Vaughn

VP of Quality & Compliance
Productive Plastics
Office: (856) 778-4300 Ext. 207 E-Mail:nvaughn@productivecompanies.com


The next generation of family leadership and ownership begins at Productive Plastics

Evan Gilham Named President of Productive Plastics

Productive Plastics has embarked on a transition of leadership to the 3rd generation of Gilham family ownership as Evan Gilham assumed his new role as President in September of this year.

Hal Gilham, former President and now CEO, announced this evolution and continued legacy of ownership at the SPE Thermoforming Conference in September after accepting the Thermoformer of the Year award for 2021 by the Society of Plastics Engineers (SPE) Thermoforming Division.

This marks the beginning of an incremental and smooth transfer of leadership and ownership of the company over the next 12-18 months. Evan Gilham comments, “During this transition, we are focused on maintaining trusted partnerships with our customers.” Evan adds, “We are committed to a future of continued innovation and expanded manufacturing services.”

The team at Productive Plastics hopes you will join us in congratulating Evan on his new role and wishing Hal good luck in his future endeavors.

Have a safe and happy holiday season!

Left to right – Evan Gilham (President) and Hal Gilham (CEO)

[Join our Free Technical Webinar] Introduction to TPO and its Advantages

Please join a complimentary webinar on OCT 27th @ 11am hosted by SIMONA PMC and Productive Plastics on the technical and cost advantages of TPO over metal and fiberglass for your applications. Explore the wide range of TPO grades available for performance or aesthetics, comparisons, case studies, details on designing for plastic thermoforming, and more!

What to Expect in this Webinar:

  • Introduction to TPO
  • Overview of the different grades of TPO, where each is used and why
  • Guidance for converting to TPO from fiberglass, gelcoat or metal
  • Advantages of using TPO in high heat applications
  • Application case studies
  • Cost comparisons
  • Material performance data 
  • Plastic thermoforming design and technical considerations
  • Moderated Q&A session
  • Complimentary Plastic Thermoforming Design Guide & Metal to Plastic Thermoforming Comparison and Conversion Guide digital downloads

Productive Plastics Exhibiting at Design-2-Part Uncasville CT June 23 & 24

Productive Plastics is excited to be exhibiting again at Design-2-Part this year. If you or any of your team will be attending the Design-2-Part show in Uncasville CT on June 23 & 24, please stop by our booths (314 & 316). Talk plastic thermoforming with our experts and get hands on with a selection of our thermoformed parts and multi-part assembly samples from solutions provided to medical device, kiosk, material handling, and other industries. Our team will be at your disposal to discuss how Productive Plastics and plastic thermoforming can add to the success of your next project.

Visit us at Booths 314 & 316

  • Advantages of heavy gauge plastic thermoforming
  • Thermoplastic material options and performance
  • Design and tooling capabilities
  • Conversions from metal, fiberglass, or injection molding processes
  • Industry applications and standards compliance
  • Assembly and surface finishing value added operations

We hope to see you at the show!

Registration for the event is free

Use your mouse to rotate and interact with feature callouts on the plastic thermoformed kiosk fascia below

Webinar Recording Available: Replacing Metal with Thermoformed Plastics

If you were unable to attend our technical webinar last week on replacing metal with thermoformed plastics, a recording of the live event is now available below and on our YouTube channel.

Technical Webinar Content

  • Cost comparisons
  • Design capabilities
  • Material performance
  • Pro tips on how to maximize your design for thermoforming
  • Sheet metal to plastic thermoforminng conversion case study
  • Moderated Q&A session


Stay tuned for future technical plastic thermoforming webinars from Productive Plastics

The Thermoforming Design Guide and Metal to Plastic Comparison and Conversion Guide, both featured in our recent webinar, can be downloaded via our technical library

Join our Free Technical Webinar – Replacing Metal with Thermoformed Plastics

Join us on May 12th at 2pm and our Chief Operations Officer, Evan Gilham, will teach you the ins and outs of the plastic thermoforming process and how it compares to steel and sheet metal fabricated designs.

Gain the technical knowledge to accurately evaluate if your sheet metal design is a prime candidate for plastic thermoforming.

Discover if converting to a plastic thermoforming design would reduce costs, increase material performance, or present enhanced design capabilities for your application.

Evan will cover some key topics and comparisons between the two processes:

  • Cost comparisons
  • Design capabilities
  • Material performance
  • Pro tips on how to maximize your design for thermoforming
  • Sheet metal to plastic thermoforminng conversion case study
  • Moderated Q&A session
  • Technical thermoforming guides available for download post

Introducing the New productiveplastics.com

The newly improved website features new graphics and images, a wider desktop browser experience, better mobile viewing, and improved usability. Changes include interactive thermoformed plastic part images, updated and expanded plastic thermoforming content, industry specific thermoforming pages, and technical information.

The new website continues to feature the Productive Ideas blog with its ongoing commentary on thermoforming technology issues. Four technical guides are also available to download:

  • Heavy Gauge Plastic Thermoforming Process and Design Guide
  • Fiberglass to Plastic Thermoforming Comparison and Conversion Guide
  • Metal to Plastic Thermoforming Comparison and Conversion Guide
  • Injection Molding to Plastic Thermoforming Comparison and Conversion Guide

Manufacturing the Team to Provide you with the Best Plastic Thermoforming Solutions

I am pleased to announce the addition of Cody Brewer as our Business Development Manager to the team at Productive Plastics.

Cody has over 7 years of experience in the process engineering and sales industry, with the greater part of his career invested in manufacturing process improvements and supporting production and engineering operations. His diverse experience in disciplines paramount to our industry enable Cody to provide insight and guidance to customers during the entire development process; from product design to finished components in your hands.

Cody will be working closely with myself and the rest of the Productive Plastics team to bring you the highest level of service, quality manufacturing, product development, and rapid solutions for the production of custom plastic thermoformed components and assemblies.

I invite you to connect with Cody to discuss how Productive Plastics can contribute to your project’s success.

Regards,
John Zerillo
VP Sales | Productive Plastics

Cody Brewer
Business Development Manager
Productive Plastics
103 West Park Dr
Mt Laurel NJ, 08054
Cell: 1-(609)-280-0040
Office: 1-(856)-778-4300 Ext. 202
E-Mail:CBrewer@Productivecompanies.com

Weighing in on Product Material Selection – Plastic, Metal, or Fiberglass

Regardless of the industry your product serves, whether it includes seating components or wall paneling for  bus, rail, or aircraft, requires enclosures or parts for medical devices, or is designed with exterior casings for industrial equipment and electrical components, lightweight material has become essential to creating the ideal product that meets the needs of the end user.

Lightweight offers numerous advantages

Reduced fuel and energy costs – mass of a vehicle has a direct relationship to fuel and energy consumption

Lowered emissions – reduced fuel and energy consumption equates to lower emissions

Reduced maintenance costs – reduction in mass correlates to longer life of components due to less load bearing stress over time (moving and mechanical components, brakes, tires, propulsion systems)

Reduced logistical costs – lighter weight parts are less expensive and easier to install, ship, relocate, or handle

Weight Comparison – Thermoplastic, Fiberglass, and Metal

Lower material specific gravity (mass) means the finished component will be lighter and contribute to a lower overall product weight. There are countless variations and formulations of thermoplastic, fiberglass, and metal materials, each with its own unique specific gravity (details can be found on material manufacturers’ websites and material data sheets). However, if you look at the average weight of some of the most common brands and types of materials available, you can derive some basic comparisons.

Plastic thermoformed parts are 6 times lighter than steel and half the weight of aluminum.

Plastic thermoformed parts are 30 – 40% lighter than fiberglass counterparts.

thermoplastic, metal, and fiberglass average specific gravity and weight comparisson

If reducing your product’s weight is an important factor in your industry, then thermoplastic and the thermoforming process should be a consideration for your current or future projects.

Please download our complimentary material – process comparison guides and conversion guides — for more information. They are full of data that is valuable to decision makers, design engineers and every member of an original equipment manufacturer (OEM) project team

Productive Plastics is more than just a plastic thermoforming manufacturer. We strive to be your advisor throughout the entire product development process by bringing over 60 years of process, design, material, and finishing expertise to assist in manufacturing your component parts and products in the best and lightest way. Contact Us for further assistance or to request a quote.

Heavy vs thin gauge plastic thermoforming – what’s the difference?

The dimensional difference between heavy gauge thermoforming (sometimes referred to as thick gauge or sheet fed thermoforming ) and thin gauge (also referred to as roll fed) thermoforming may only start as a few tenths of an inch in part thickness, but the manufacturing techniques, machinery required, and scope of applications that the two are best suited for are quite distinct from one another.

Additionally, because the machinery required is unique for each process category, most plastic thermoforming manufacturers specialize in only one or the other. For instance, Productive Plastics is a custom heavy gauge plastic thermoforming manufacturer. So, you can save some time when searching for a processor if you know which category of thermoforming is the right solution for your application.

Here are the essential differences between heavy and thin gauge plastic thermoforming:

Plastic Thermoforming Heavy Gauge Thin Gauge
Manufactured Part Thickness (approximate) .060 -.375″ 1.5 – 9.5 mm < .125” < 3mm
Machinery Type Sheet Fed Roll Fed
Thermoplastic Materials Used (Most Common) ABS
Polycarbonate
HDPE
Polypropylene (many material variants available)
PETG
PET
Clear PVC
Styrene
Polypropylene  
Annual Volume Low – Mid Volume < 10,000 High Volume > 10,000
Typical Applications -Medical device enclosures
-Transportation interior parts (window masks, wall and ceiling panels, seating, luggage racks)
-Kiosk enclosures
-Industrial equipment covers
-Electronic equipment enclosures
-Clamshell packaging
-Food service packaging
-Disposable cups, plates, and trays
-Food containers
-Small medical device packaging

Does your application favor heavy gauge thermoforming? If so, contact us or download our Heavy Gauge Plastic Thermoforming Design Guide for more detailed  information on the features and benefits of plastic thermoforming and to explore how Productive Plastics can provide manufacturing solutions for your product.

Please contact Productive Plastics for more information on the thermoforming process
Please download the heavy gauge thermoforming design guide from Productive Plastics

Terminology Note

Productive Plastics and the plastics industry typically use the terms "vacuum forming" and "vacuum thermoforming" interchangeably. Misspellings include "vacuumforming" and "vacuumthermoforming".

Looking for more technical information?

Download the Thermoforming Design Guide, Process Comparisons, Conversion Guides, and other useful thermoforming information from our technical resource library.

Contact Us

Ready to explore how Productive Plastics can add to the success of your project?