Thermoforming is a fabrication process in which sheets of plastic are first heated and then placed over or inside of a mold. When cooled, the plastic hardens and retains the mold's shape. Faro Industries of Rochester, NY has been a leader in custom plastic fabrication since 1967, manufacturing products for retail, medical, electronic, military, and scientific applications.

The primary thermoforming methods are:

• Vacuum Forming: Sheets of warmed thermoplastic are placed over a male or female mold, and suction is applied to shape the plastic tightly against the mold so that it picks up even the most minute contours. Once the detail transfer is complete, a water cooling system within the mold cools the plastic. When it reaches the appropriate temperature, gusts of air blown through the mold remove the hardened thermoplastic.
• Pressure Forming: Sheets of warmed thermoplastic are transferred to a forming station, where an upper mold (or pressure box) and a lower mold come together to shape the plastic. Gusts of compressed air from the pressure box press the thermoplastic tightly against the mold to achieve high-definition detail transfers. Pressure forming allows design flexibility and results in products with high structural integrity.
• Twin Sheeting: This process is a hybrid of vacuum and pressure thermoforming, in which two sheets of thermoplastic are created with different molds. These are then form-welded together to form a hollow between them, into which the manufacturer can place inserts or inject rigid foam for greater structural integrity.

Thermoforming is adaptable to your individual needs, and reduces prototyping times. It is an inexpensive process, and is appropriate for just-in-time manufacturing. Colored and paintable plastics are available.

For your custom plastic needs, contact Faro Industries of Rochester, NY. They design and build all of their own internal forms and tools. Because of that, you will enjoy more responsive communication and quicker turnaround times throughout your prototype's development process. For more information, visit them online, or call (585) 647-6000 today.