Thermoforming (TF)

Thermoforming, also known as hot forming, vacuum forming or deep drawing, is a proven method for processing thermoplastics. This process enables the production of precise, functional components for numerous industrial applications. At C.F. Maier-TEC, we use thermoforming to transform thermoplastic sheets such as ABS, PVC and PE into high-quality components with precise contours and attractive surfaces.

The thermoforming process

In thermoforming, the semi-finished product, usually a thermoplastic sheet, is first clamped in a machine and heated evenly from both sides. As soon as the sheet has reached the required forming temperature, it is pulled over an aluminum mould. With the help of compressed air and vacuum, the sheet adapts to the mold and takes on its contour. Trapped air escapes through special openings in the tool, ensuring a perfect fit.

After cooling, the molded plastic component is removed and trimmed with a CNC milling machine to achieve the exact final contour. This process ensures precise, dimensionally accurate components, which are particularly important in the automotive industry, medical technology and mechanical and apparatus engineering. The post-processing step ensures high dimensional accuracy and clean processing, which is particularly important for technical applications.

Materials and versatility

Thermoforming offers a very large selection of sheet materials, materials, colors and shapes, making it an ideal solution for a wide range of applications. At C.F. Maier-TEC, we process a wide range of common thermoplastics in thermoforming, including

• ABS (acrylonitrile butadiene styrene)
• ASA (acrylonitrile-styrene-acrylic ester)
• PMMA (polymethyl methacrylate)
• PE (polyethylene)
• PP (polypropylene)
• PS (polystyrene)
• PC (polycarbonate)
• PETG (polyethylene terephthalate glycol)
• PVC (polyvinyl chloride)

These materials each offer specific mechanical properties, surface qualities and thermal resistance and are therefore suitable for a wide range of applications. The choice of material depends on the individual requirements of the respective project, and we will be happy to advise you on the selection of the right material.

The possible applications of thermoforming at C.F. Maier-TEC include the following sectors

• Commercial vehicles and motorhomes: cladding and interior elements
• Medical technology: housings and covers for medical devices
• Machine and apparatus construction: covers and functional components

Advantages of thermoforming

Thermoforming is suitable both for the production of individual parts and for complex system solutions, which are often created in combination with polyurethane, for example in the automotive industry or medical technology.

• Versatile choice of materials: Thanks to the wide range of thermoplastic materials, various requirements can be met.
• High precision and surface quality: The use of aluminum moulds and the combination of compressed air and vacuum ensure precise shaping and high-quality surfaces.
• Cost-efficient production: Thermoforming offers a cost-effective solution, especially for medium to large series sizes.
• Fast production times: Due to the short cycle times, thermoforming enables fast and efficient production of components, resulting in significant cost savings.
• Flexibility in design and size: From small components to large-scale cladding, thermoforming offers a high degree of flexibility in design.

Recyclability of thermoplastics

Another advantage of thermoforming is the recyclability of thermoplastics. Many of the materials used, such as ABS, PE, PP and PETG, can be recycled at the end of their life cycle. This makes thermoforming not only an economical solution, but also an environmentally friendly one. At C.F. Maier-TEC, we attach great importance to sustainability and support our customers in the selection of recyclable materials to ensure environmentally conscious production.

Conclusion

Thermoforming is a flexible and efficient process for manufacturing high-quality components from thermoplastics. It enables precise shaping, a wide range of materials and economical production. At C.F. Maier-TEC, we offer you comprehensive services in the field of thermoforming, from material consulting to processing and CNC post-processing of the component. We are happy to support you in finding the optimum solution for your specific requirements.