Understanding Heavy vs thin gauge plastic thermoforming
While the difference in starting thickness 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 begin as a few tenths of an inch in part thickness, the two are utilized in different applications than one another as the manufacturing techniques, machinery required, and project scope differ.
The machinery required is unique for each process category, meaning 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.
