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 |
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Heavy Gauge – Medical Device Enclosure 
Thin Gauge – Food 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.
Ensuring that your manufacturer has adopted an accredited quality control program, such as ISO 9001, will indicate that the company has an active quality control process in place that has been evaluated and certified by an industry recognized third party. The accreditation documentation, often available on the manufacturer’s website, will give you detailed information on what aspects of the company have been certified and supporting quality documentation can often be requested from the processor.
to a company’s commitment to quality. A company with a well-organized manufacturing floor is much more likely to take quality, efficiency, process improvement, and safety seriously. If you are not offered a tour of the facility, ask for ne and witness firsthand the quality control measures in action. Cleanliness and organization are vital since thermoforming is an “open mold process” meaning airborne dirt could end up as an inclusion in the finished part and become a cosmetic flaw.
Summit, hosted by Productive Plastics, you will learn about every aspect of developing a new product or converting an existing project to the plastic thermoforming manufacturing process.You will gain insights about the entire development process, from design to finished assembly, as you engage with industry leaders from each link in the production supply chain.
muffin molds and you imagine the impact on production and cost. In fact, most standard injection molding machines can only accommodate a maximum part size of 4’ x 4’. Larger machinery is available but is also drastically more expensive.
ISO 9001:2015
