Twin Sheet Vacuum Form Molds

Castek is a leading manufacturer specializing in custom twin-sheet formed plastics for a variety of applications. We have many years of product design and manufacturing experience. Our goal is to provide our clients with the highest level of technical expertise. Using twin sheet thermoforming process we create quality parts for a wide range of industrial and commercial needs.


The Challenges of Twin Sheet Forming

Twin sheet forming can be a complex process. It requires a high level of accuracy when aligning the sheets of plastic together. The technician must have the expertise to understand the right conditions that would give rise to a successful process. 

For example, between the pressed joints there can’t be a difference of more than 0.006 of an inch. A bigger difference would cause one of the sheets to buckle distorting the plastic. Additionally, care must be taken not to allow hot air to be trapped inside. One solution is to add a ventilation system that allows cool air to circulate.

Twin Sheet Forming Applications

Despite these challenges, twin sheet forming has many advantages over other plastic forming methods. The thermoforming process creates parts with high strength and firmness coupled with low-density. For this reason, it is used for making enclosures for electronic parts and medical equipment. Thanks to the resulting strength and firmness, the process is now used to make some exterior parts and components in trucks and buses.

The excellent features of the twin sheet formed plastic panels also make them suitable for the following applications:

  • Truck bed liners
  • Portable toilets
  • Vending machine chutes
  • Enclosures for electronic components
  • Fuel Containers
  • Carrying cases and storage containers
  • Etc…

You can gain a lot from using the twin sheet thermoforming process. However, you need to be clear on your objectives and what to expect. Our experts in plastic forming can help you make the right decisions on which process to choose. 

Here are some of the advantages that may make plastic sheet forming suitable for your applications:

  • Double-walled thermoforming results in structures with higher strength than a single-walled process. This makes it suitable for making containers or enclosures that require rigidity and consistent form. 
  • Compared to blow molding it can bring reduce tooling costs down to 30%.
  • A unique process of thermoforming makes it possible to place internal components inside it. Manufacturers can create air ducts for larger components to discourage the accumulation of heat. Depending on the project, it may be necessary to place wiring inside the compartments which improves the part’s capabilities for a specific application.
  • Twin sheet forming is used for a wide range of projects, because the parts can be formed into different shapes and sizes. The manufacturer can create a product with various textures and colors to suit the client’s needs. It has enhanced aesthetics thanks to the use of tooling on both sides of the plastic panels.

The Challenges of Twin Sheet Technology

The challenge for the manufacturer is to take two sheets of plastic and turn them into accurately designed double-walled and hollow components. To create these parts accurately, the two sheets are heated together on two separate molds. 

The mold keeps the two sheets apart, as the vacuum is used to push the edges together and create a hollow interior. The result is an aesthetic pleasing, precise 3-dimensional part, with strong and stable joints.

There are many different materials types that can be used dependent on the application:

  1. PVC and Acrylic: Used for residential applications and in areas where adherence to the high flammability standards is required.
  2. TPO (Thermoplastic Polyolefins): Suitable for applications where resistance to high impact is needed. This material also exhibits great performance when subjected to extreme temperature fluctuations.
  3. ABS (Acrylonitrile Butadiene Styrene): Has features that include chemical resistance and has high impact strenght.
  4. HDPE (High Density Polyethylene Sheets): HDPE is cost effective and also suitable for high impact strength projects.
  5. HIPS (High Impact Polystyrene): HIPS is lightweight and low cost and is common for fast food packaging and can be used for a wide range of household goods.

Castek can guide you through the process of choosing materials and planning your project. Contact our friendly helpdesk today for any queries, or to request a free quote for twin forming sheets manufacturing.