Project Description

你有没有想过有多大的塑料碎片,比如飞机的厨房和挡风玻璃, interior panels and bumpers of cars, hospital beds, large office printers, ATM machines – are made? 那么像实验室里的试管架这样的小塑料碎片呢, blister pill packaging, and food containers? 它们都有一个共同点:塑料热成型.

 

What is Plastic Thermoforming?

塑料热成型是一种制造塑料零件的过程,其中涉及到加热塑料片,直到他们变得柔韧和易受影响,被塑造成所需的形式. Hence the words ‘thermo’ and ‘forming’.

 

Why is Plastic Thermoforming important?

而塑料热成形可以制造不同尺寸和厚度的多种塑料, 从薄的塑料包装到又大又厚的塑料零件, it is especially important to a product’s design. Specifically, to enclosure design and weight.

 

Enclosure Design

外壳设计是产品最重要的组成部分之一, and usually also the most time-consuming and costly. 塑料热成形是产品设计中需要考虑的重要工艺,因为热成形所能生产的零件非常大, or small, for enclosure purposes.

热成形过程也可以创造非常美观的塑料, such as those with colors or textures, 不需要额外的抛光或油漆(这两者都可能是增加成本的元素).

 

Weight

通过热成型制造的塑料可以作为重要的产品的替代材料. 如果你考虑汽车和飞机上使用的部件,重量就成了一个敏感因素. 因此,热成型塑料提供了一个轻而坚固的替代钣金产品.

 

How does Plastic Thermoforming work?

Plastic thermoforming – be it vacuum thermoforming, pressure thermoforming or mechanical thermoforming -首先加热一片塑料(厚或薄取决于最终产品的规格),使其高度柔韧.

柔韧的塑料片然后放置在一个模具上-这是逆向设计的 & 设计到所需的塑料产品-并通过吸力作用向模具拉(vacuum thermoforming). At the same time, a downward pressure (pressure thermoforming) or a plug (mechanical thermoforming)可用于在塑料板上施加额外的压力,以进一步提高成型工艺的精度和提高塑料零件的美观性.

加热后的塑料板继承模具的形状,成为所需的塑料产品, it is then rapidly cooled and trimmed. The plastic is now ready for use!

 

塑料热成型与塑料注射成型相比有哪些优势?

塑料热成型的优势可以从模具,交货期,零件尺寸 & complexity, and aesthetics of the plastic.

 

Tooling

Tooling here refers to the process of mold creation. In comparison to plastic injection molding, 塑料热成型的模具成本显著降低, 而且模具本身制作速度更快,因为只需要一个单面模具. Once made, the tool can be used for a life-time, 使它非常适合生产大量的塑料零件.

Given the relative rapidity of tooling, 热成型还为产品的设计微调提供了更多的余地, and creating savings in tooling investment.

 

Lead-times

因为模具加工比塑料注射成型快得多, 塑料热成型的最终交货时间也短得多.

 

Part size & complexity

塑料热成型可以制造出塑料注射成型无法生产的大块塑料零件. 塑料热成型可以产生高达10英寸× 18英寸的零件尺寸,并可以将多个零件合并成一个大零件. 另一方面,塑料注射成型只能产生很小的零件与最小的巩固.

 

Aesthetics of plastic

Thermoformed plastic is quite aesthetically pleasing, 因为纹理和图案可以预先设计到工具中. 与此同时,它也足够美观,即使没有油漆使用. 相比之下,塑料注射成型需要对产品进行额外的整理.

Moreover, 季节是有能力的双片形成,这允许对比色出现在一个部分, allow for differences in thickness, hollow parts & 内部加固,多种纹理和墙体尺寸.

 

Is thermoformed plastic sustainable?

Thermoforming in itself is a process, 因此,热成型塑料部件的可持续性取决于生产它所使用的材料, 是否在零件上添加了额外的化学物质,零件的最终用途是什么.

然而,一些热成型塑料可以回收并再生为树脂以供进一步使用. The material ABS for example is recyclable, 而且往往被用于生产更耐久的产品,如玩具和行李,而不是一次性塑料产品.

Other materials, 特别是那些钢网强度高的,如聚碳酸酯, Kydex and Boltaron, tend to also be more rigid and sustainable. 这些塑料尤其经常用于航空航天项目.

 

Plastic Thermoforming at Season Group

在季节,塑料热成型是我们的制造能力之一. 从采购塑料,逆向工程,到内部模具(i.e. 特定零件/产品的模具制作和产品的微调, Season为塑料热成型提供一站式服务.

In fact, 我们的马来西亚站点拥有马来西亚和东南亚最大的热成型机器之一. We are even AS9100 certified for thermoforming, 这让我们成为航空航天和国防工业客户的可靠供应商.

季节也能够组装您的热成型塑料零件. Be it a small plastic component or a large case, 它可以与它的其他部件在季节组装, even when it involves components of other materials.

 

Concluding Remark

Plastic thermoforming is a choice plastic process, especially if you’re looking to produce large, bulky plastic parts. The process has low tooling costs, a short lead time, and produces aesthetic, textured parts that are choice for enclosure design.