Injection Molding vs Thermoforming
Plastic Thermoforming Process vs. Injection Molding – How to Choose?
Injection molding and the plastic thermoforming process both have widespread uses in a long list of industries. Each process has some unique features and benefits that are often advantageous for a specific application. In these instances, the choice to manufacture with plastic thermoforming or injection molding may have been easily made in years past.
However, as advances in manufacturing technology continue to evolve, the area where a product’s needs and the capabilities of plastic thermoforming and injection molding overlap is increasing. Selecting the right method in these situations requires a deeper appraisal of the features, benefits, and costs associated with each process.
Comparing Plastic Thermoforming and Injection Molding
The choice to manufacture with plastic thermoforming or injection molding may at time be very obvious. This is most apparent in production volume. Low to mid volume tends to favor thermoforming, while high volume is usually more cost effective with injection molding. This is due primarily to differences in tooling complexity and cost between the two processes.
However, a product’s needs and the capabilities of these two processes sometimes overlap. A part’s geometry may seem better suited for injection molding, but in a limited production run, it may be drastically more cost effective to manufacture it with plastic thermoforming. This is just one example of an application where deciding between injection molding and plastic thermoforming may not be a clear choice.
Plastic Thermoforming Key Points
Injection Molding Key Points
Product Development Cycle
The combination of tooling and production time provides a measure of comparison. For thermoforming (pressure forming), the typical tooling time is 0-8 weeks, and first production typically happens within 2 weeks of that. With injection molding, tooling usually takes 12-16 weeks with up to four more weeks for production.
If time-to-market is an important consideration, thermoforming may be the preferred manufacturing technology

Part Cost Comparison

The cost comparison chart uses the total aggregate cost of parts and tooling for a large plastic part. Total part cost is substatially lower for thermoforming below about 3,000 - 5,000 parts but beyond this volume, injection molding per part cost is typically more competitive. This is driven primarily by the difference in tooling costs between each processes.
Compare More Benefits and Key Manufacturing Data of Plastic Thermoforming and Injection Molding Processes
Above are just a few statistics and comparisons for plastic thermoforming and injection molding. Choosing the right plastic manufacturing process that fits your project’s unique manufacturing needs can be daunting. That’s why Productive Plastics has developed this comparison and selection guide for plastic thermoforming and injection molding processes. Inside you’ll find additional information that is valuable to manufacturing decision makers, design engineers and every member of an original equipment manufacturer (OEM) project team.
Click here to download Productive Plastics’ Plastic Thermoforming & Injection Molding Manufacturing Process Comparison and Selection Guide (PDF) now.
Click here to download Productive Plastics’ Plastic Thermoforming & Injection Molding Manufacturing Process Comparison and Selection Guide (PDF) now.