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With ESD and EMC protection, high impact resistance, and dust/moisture resistance, they meet safety-critical requirements.\u003C/p>\u003Cp>\u003Cstrong>Subcategories of defense housings:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Sensor housings:\u003C/strong> for cameras, LiDAR, or infrared sensors\u003C/li>\u003Cli>\u003Cstrong>Communication system housings:\u003C/strong> for radios and encryption modules\u003C/li>\u003C/ul>",{"id":257,"documentId":258,"name":259,"alternativeText":260,"caption":16,"width":168,"height":168,"formats":444,"hash":277,"ext":148,"mime":151,"size":278,"url":279,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":280,"updatedAt":280,"publishedAt":281},{"avatar":445,"default":446,"thumbnail":447},{"ext":148,"url":263,"hash":264,"mime":151,"name":265,"path":85,"size":266,"width":195,"height":195},{"ext":148,"url":268,"hash":269,"mime":151,"name":270,"path":85,"size":271,"width":202,"height":202},{"ext":148,"url":273,"hash":274,"mime":151,"name":275,"path":85,"size":276,"width":210,"height":210},[449],{"id":450,"visible":228,"label":451,"link":452,"variant":438},945,"More about Electronic Enclosures","/products/electronic-enclosures",{"id":454,"title":455,"text":456,"sidebar_information":85,"image":457,"buttons":464},613,"Protective & Paneling Parts for Interior & Exterior Use","\u003Cp>Plastic paneling parts for aerospace and defense are used as outer and inner covers, device hoods, modular panels, or cabin panels. They are applied in military vehicles, cockpits, and aircraft cabins. Defense paneling parts are UV-stable, chemical-resistant, highly impact-resistant, and meet strict fire protection and design requirements.\u003C/p>\u003Cp>\u003Cstrong>Advantages of defense paneling parts:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>UV-stable & chemical-resistant for harsh environments\u003C/li>\u003Cli>vibration-resistant, noise-reducing (NVH improvement possible)\u003C/li>\u003Cli>quick to replace/repair thanks to modular design\u003C/li>\u003C/ul>",{"id":335,"documentId":336,"name":337,"alternativeText":338,"caption":338,"width":339,"height":339,"formats":458,"hash":368,"ext":342,"mime":345,"size":369,"url":370,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":371,"updatedAt":372,"publishedAt":373},{"md":459,"sm":460,"avatar":461,"default":462,"thumbnail":463},{"ext":342,"url":343,"hash":344,"mime":345,"name":346,"path":85,"size":347,"width":161,"height":161},{"ext":342,"url":349,"hash":350,"mime":345,"name":351,"path":85,"size":352,"width":168,"height":168},{"ext":342,"url":354,"hash":355,"mime":345,"name":356,"path":85,"size":357,"width":195,"height":195},{"ext":342,"url":359,"hash":360,"mime":345,"name":361,"path":85,"size":362,"width":202,"height":202},{"ext":342,"url":364,"hash":365,"mime":345,"name":366,"path":85,"size":367,"width":210,"height":210},[465],{"id":466,"visible":228,"label":467,"link":36,"variant":438},946,"More about Plastic Enclosures",{"id":469,"title":470,"text":471,"sidebar_information":85,"image":472,"buttons":477},614,"Plastic Housings & Fuselage Panels for Drones & UAV Systems","\u003Cp>Drone housings and fuselage panels made of plastic protect UAV systems in civil and military applications. Covers, fuselage parts, or payload carriers provide lightweight, precise protection against environmental and mechanical stress. They are light, robust, UV- and chemical-resistant, and can be flexibly adapted through fast iterations and small-batch production.\u003C/p>\u003Cp>\u003Cstrong>Advantages of fuselage panels and drone housings:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>lightweight = greater range/payload\u003C/li>\u003Cli>fast design iterations from prototype → pilot series → mass production\u003C/li>\u003Cli>optional ESD/EMC protection concepts for payload electronics\u003C/li>\u003C/ul>",{"id":283,"documentId":284,"name":285,"alternativeText":286,"caption":16,"width":168,"height":168,"formats":473,"hash":303,"ext":148,"mime":151,"size":304,"url":305,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":306,"updatedAt":307,"publishedAt":308},{"avatar":474,"default":475,"thumbnail":476},{"ext":148,"url":289,"hash":290,"mime":151,"name":291,"path":85,"size":292,"width":195,"height":195},{"ext":148,"url":294,"hash":295,"mime":151,"name":296,"path":85,"size":297,"width":202,"height":202},{"ext":148,"url":299,"hash":300,"mime":151,"name":301,"path":85,"size":302,"width":210,"height":210},[478],{"id":479,"visible":228,"label":480,"link":36,"variant":438},947,"More about Plastic Covers",{"__component":375,"id":482,"title":483,"variant":484,"size":226,"introduction":85,"benefits":485,"style":569},605,"Advantages of Plastic Thermoformed Parts for Aerospace & Defense","horizontal",[486,500,514,528,542,557],{"id":487,"title":488,"text":489,"icon":490},2617,"Lightweight Design","Thermoformed plastic parts enable significant weight savings compared to metal parts while maintaining high impact resistance and stability.",{"id":491,"documentId":492,"name":493,"alternativeText":494,"caption":494,"width":389,"height":389,"formats":85,"hash":495,"ext":392,"mime":393,"size":496,"url":497,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":498,"updatedAt":498,"publishedAt":499},643,"rdpdqsv08ua1euqory96vtqs","Viereckige Blöcke_Icon.svg","Viereckige Blöcke_Icon","Viereckige_Bloecke_Icon_88ce23f5ba",1.14,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Viereckige_Bloecke_Icon_88ce23f5ba.svg","2023-11-09T15:43:50.000Z","2026-01-08T22:03:04.295Z",{"id":501,"title":502,"text":503,"icon":504},2618,"Design Freedom","Thermoforming allows complex geometries, customized surfaces, and ergonomic designs. Cabin panels, defense housings, and drone housings can be tailored to technical and aesthetic requirements.",{"id":505,"documentId":506,"name":507,"alternativeText":508,"caption":508,"width":389,"height":389,"formats":85,"hash":509,"ext":392,"mime":393,"size":510,"url":511,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":512,"updatedAt":512,"publishedAt":513},658,"u4huox9ryewrj8k369bosegh","Corporate Design_Icon.svg","Corporate Design_Icon","Corporate_Design_Icon_0b177dabf0",0.58,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Corporate_Design_Icon_0b177dabf0.svg","2023-11-10T19:55:47.000Z","2026-01-08T22:03:06.270Z",{"id":515,"title":516,"text":517,"icon":518},2619,"Cost Efficiency","Prototypes and small series are more economical to produce compared to injection molding or CNC. Low tooling costs and rapid iterations reduce both development time and overall costs.",{"id":519,"documentId":520,"name":521,"alternativeText":522,"caption":16,"width":389,"height":389,"formats":85,"hash":523,"ext":392,"mime":393,"size":524,"url":525,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":526,"updatedAt":526,"publishedAt":527},1739,"h4vwrx7v4f63nztolhhbdf14","Geld_Icon.svg","Geld_Icon","Geld_Icon_aea04fb4f3",0.81,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Geld_Icon_aea04fb4f3.svg","2024-11-11T16:40:06.000Z","2026-01-08T22:05:30.330Z",{"id":529,"title":530,"text":531,"icon":532},2620,"Compliance With Standards","All materials used meet relevant aerospace and defense standards, such as flame protection according to UL94 V-0 or FAR 25.853, as well as ESD and EMC protection requirements and UV resistance.",{"id":533,"documentId":534,"name":535,"alternativeText":536,"caption":16,"width":389,"height":389,"formats":85,"hash":537,"ext":392,"mime":393,"size":538,"url":539,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":540,"updatedAt":540,"publishedAt":541},931,"hi896sagoronsbtzkdcoz4lz","Liste_Icon.svg","Liste_Icon","Liste_Icon_5cea0d389d",0.68,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Liste_Icon_5cea0d389d.svg","2024-02-21T11:55:49.000Z","2026-01-08T22:03:42.971Z",{"id":543,"title":544,"text":545,"icon":546},2621,"Short Lead Times","Through digital processes and the use of bridge tooling, prototypes and series components can be produced quickly and reliably. A clear advantage for time-critical A&D projects.",{"id":547,"documentId":548,"name":549,"alternativeText":550,"caption":16,"width":389,"height":389,"formats":85,"hash":551,"ext":392,"mime":393,"size":552,"url":553,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":554,"updatedAt":555,"publishedAt":556},49,"gxg5fbb5eldkzmvlu47xbohe","Zeit_Icon","Zeit und Aufwand sparen_Schnelle Abwicklung_Icon","times_5268ebcf86",0.62,"https://fsn1.your-objectstorage.com/formary-de-production-cms/times_5268ebcf86.svg","2021-05-31T15:10:31.000Z","2024-07-10T16:37:44.000Z","2026-01-08T22:01:45.646Z",{"id":558,"title":559,"text":560,"icon":561},2622,"Safety","Plastic parts for defense and aerospace are impact-resistant, chemical-resistant, and withstand extreme environments. They ensure reliable function in cockpits, UAVs, and military communication systems.",{"id":454,"documentId":562,"name":563,"alternativeText":564,"caption":16,"width":389,"height":389,"formats":85,"hash":565,"ext":392,"mime":393,"size":552,"url":566,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":567,"updatedAt":567,"publishedAt":568},"e1eiiiwpujuzvmvb5cq81722","Messung_Icon.svg","Messung_Icon","Messung_Icon_b7e2257fa7","https://fsn1.your-objectstorage.com/formary-de-production-cms/Messung_Icon_b7e2257fa7.svg","2023-10-31T18:51:04.000Z","2026-01-08T22:03:00.463Z",{"id":570,"background":419,"border":85},1018,{"__component":572,"id":573,"title":574,"textblocks":575},"page-template.textblocks",74,"Key Plastics for Defense Applications",[576,582,586,590,594,598,602,606],{"id":577,"title":578,"text":579,"variant":580,"width":581,"cta_button":85},131,"ABS/PC-Blend","High impact strength, good temperature resistance, dimensionally stable; used for device covers and electronic assemblies.","boxed","half",{"id":583,"title":584,"text":585,"variant":580,"width":581,"cta_button":85},132,"HIPS (High Impact Polystyrene)","Lightweight, impact-resistant, easy to form, cost-efficient; used for internal defense covers and prototypes.",{"id":587,"title":588,"text":589,"variant":580,"width":581,"cta_button":85},133,"PMMA/ABS (e.g. Senosan)","Excellent surface quality, scratch-resistant, UV-stable; used for visible housings and display protection.",{"id":591,"title":592,"text":593,"variant":580,"width":581,"cta_button":85},134,"PEEK","Extremely temperature- and chemical-resistant, flame-retardant, high-cost high-end material; used for high-security housings and sensor components.",{"id":595,"title":596,"text":597,"variant":580,"width":581,"cta_button":85},135,"FR-ABS (flame-retardant ABS)","UL94 V-0 flame protection, robust and dimensionally stable; used for interior panels requiring fire safety.",{"id":599,"title":600,"text":601,"variant":580,"width":581,"cta_button":85},136,"PVC/ASA","Chemical-resistant, UV-stable, suitable for outdoor use; used for external covers and communication modules.",{"id":603,"title":604,"text":605,"variant":580,"width":581,"cta_button":85},137,"PET-G","Transparent, shatterproof, dimensionally stable, food-safe; used for viewing windows and protective parts in laboratory environments.",{"id":607,"title":608,"text":609,"variant":580,"width":581,"cta_button":85},138,"Conductive ABS (e.g. ABS-ESD)","ESD-safe and conductive, specially developed for electronics protection; used for housings requiring EMC/ESD protection.",{"__component":611,"id":612,"buttons":613},"page-template.button",154,[614],{"id":615,"visible":228,"label":616,"link":617,"variant":225},943,"Learn more about Materials","/materials",{"__component":375,"id":619,"title":620,"variant":378,"size":226,"introduction":621,"benefits":622,"style":681},606,"How Does formary Support the A&D Industry?","formary is your digital manufacturer for plastic thermoformed parts in aerospace and defense.",[623,639,644,649],{"id":624,"title":625,"text":626,"icon":627},2623,"Prototypes & Small Series","formary enables cost-efficient production of aerospace components and defense housings.",{"id":628,"documentId":629,"name":630,"alternativeText":631,"caption":16,"width":632,"height":14,"formats":85,"hash":633,"ext":392,"mime":393,"size":634,"url":635,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":636,"updatedAt":637,"publishedAt":638},38,"kzf86uibhaf2sq1lgamlahfq","stack.svg","Stapel_Icon",46,"stack_dadefb7b58",0.92,"https://fsn1.your-objectstorage.com/formary-de-production-cms/stack_dadefb7b58.svg","2021-05-14T17:39:00.000Z","2023-09-29T16:00:47.000Z","2026-01-08T22:01:44.348Z",{"id":640,"title":641,"text":642,"icon":643},2624,"Cost Advantages","Thermoformed defense parts offer significantly lower tooling costs compared to CNC or injection molding.",{"id":519,"documentId":520,"name":521,"alternativeText":522,"caption":16,"width":389,"height":389,"formats":85,"hash":523,"ext":392,"mime":393,"size":524,"url":525,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":526,"updatedAt":526,"publishedAt":527},{"id":645,"title":646,"text":647,"icon":648},2625,"Fast Project Execution","formary provides digital processes, 100+ manufacturing partners, and reliable capacities for your defense housings and trays.",{"id":547,"documentId":548,"name":549,"alternativeText":550,"caption":16,"width":389,"height":389,"formats":85,"hash":551,"ext":392,"mime":393,"size":552,"url":553,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":554,"updatedAt":555,"publishedAt":556},{"id":650,"title":651,"text":652,"icon":653},2626,"Confidentiality & Security","formary ensures that your project data and design plans are protected – a critical factor for safety-relevant industries like aerospace and defense.",{"id":654,"documentId":655,"name":656,"alternativeText":657,"caption":85,"width":658,"height":658,"formats":659,"hash":675,"ext":148,"mime":151,"size":676,"url":677,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":678,"updatedAt":679,"publishedAt":680},979,"g4swpommiyyh18k8l46061b4","Schutzschild_Icon.png","Schutzschild_Icon",500,{"avatar":660,"default":665,"thumbnail":670},{"ext":148,"url":661,"hash":662,"mime":151,"name":663,"path":85,"size":664,"width":195,"height":195},"https://fsn1.your-objectstorage.com/formary-de-production-cms/avatar_Schutzschild_Icon_3397ab1ef0.png","avatar_Schutzschild_Icon_3397ab1ef0","avatar_Schutzschild_Icon.png",6.66,{"ext":148,"url":666,"hash":667,"mime":151,"name":668,"path":85,"size":669,"width":202,"height":202},"https://fsn1.your-objectstorage.com/formary-de-production-cms/default_Schutzschild_Icon_3397ab1ef0.png","default_Schutzschild_Icon_3397ab1ef0","default_Schutzschild_Icon.png",32.67,{"ext":148,"url":671,"hash":672,"mime":151,"name":673,"path":85,"size":674,"width":210,"height":210},"https://fsn1.your-objectstorage.com/formary-de-production-cms/thumbnail_Schutzschild_Icon_3397ab1ef0.png","thumbnail_Schutzschild_Icon_3397ab1ef0","thumbnail_Schutzschild_Icon.png",8.44,"Schutzschild_Icon_3397ab1ef0",13.63,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Schutzschild_Icon_3397ab1ef0.png","2024-03-11T16:44:24.000Z","2024-12-04T16:57:26.000Z","2026-01-08T22:03:49.273Z",{"id":682,"background":683,"border":85},1019,"grey",{"__component":685,"id":210,"title":686,"text":687,"image":688,"cta_button":738},"page-template.banner","Calculate your plastic thermoformed part for your defense application now.","Plastic thermoforming in the defense industry for small and large series | Prototyping & 3D printing sampling | On-demand manufacturing of defense trays, defense housings, cabin panels, drone covers & defense components",{"id":689,"documentId":690,"name":691,"alternativeText":691,"caption":16,"width":189,"height":182,"formats":692,"hash":732,"ext":342,"mime":345,"size":733,"url":734,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":735,"updatedAt":736,"publishedAt":737},125,"lx55hbcdoyrexb5y9ya0ihzy","Bauteile im Kunststofftray ",{"lg":693,"md":698,"sm":704,"xl":709,"2xl":714,"default":720,"thumbnail":726},{"ext":342,"url":694,"hash":695,"mime":345,"name":696,"path":85,"size":697,"width":154,"height":161},"https://fsn1.your-objectstorage.com/formary-de-production-cms/lg_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","lg_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","lg_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",59.05,{"ext":342,"url":699,"hash":700,"mime":345,"name":701,"path":85,"size":702,"width":161,"height":703},"https://fsn1.your-objectstorage.com/formary-de-production-cms/md_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","md_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","md_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",33.16,576,{"ext":342,"url":705,"hash":706,"mime":345,"name":707,"path":85,"size":708,"width":168,"height":202},"https://fsn1.your-objectstorage.com/formary-de-production-cms/sm_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","sm_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","sm_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",24.47,{"ext":342,"url":710,"hash":711,"mime":345,"name":712,"path":85,"size":713,"width":175,"height":183},"https://fsn1.your-objectstorage.com/formary-de-production-cms/xl_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","xl_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","xl_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",93.66,{"ext":342,"url":715,"hash":716,"mime":345,"name":717,"path":85,"size":718,"width":182,"height":719},"https://fsn1.your-objectstorage.com/formary-de-production-cms/2xl_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","2xl_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","2xl_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",119.32,1080,{"ext":342,"url":721,"hash":722,"mime":345,"name":723,"path":85,"size":724,"width":202,"height":725},"https://fsn1.your-objectstorage.com/formary-de-production-cms/default_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","default_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","default_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",15.63,360,{"ext":342,"url":727,"hash":728,"mime":345,"name":729,"path":85,"size":730,"width":731,"height":210},"https://fsn1.your-objectstorage.com/formary-de-production-cms/thumbnail_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","thumbnail_Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9","thumbnail_Bild3_0203_bit_002_lp_transport_lagerung_.jpg",4.65,208,"Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9",217.63,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Bild3_0203_bit_002_lp_transport_lagerung_c49975d8b9.jpg","2021-06-30T16:56:14.000Z","2024-04-10T11:40:53.000Z","2026-01-08T22:01:55.154Z",{"id":739,"visible":228,"label":740,"link":244,"variant":245},941,"Request a quote",{"__component":742,"id":743,"title":744,"variant":378,"first_accordion_open":228,"accordions":745},"page-template.accordion",513,"FAQ – Frequently Asked Questions about Thermoformed Parts for Aerospace & Defense",[746,750,754,758,762,766],{"id":747,"title":748,"content":749},3180,"What are plastic thermoformed parts used for in aerospace and defense?","\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">They are used for cabin panels, defense housings, drone housings, workpiece carriers, trays, protective covers, and ESD-protected electronic housings.\u003C/span>\u003C/p>",{"id":751,"title":752,"content":753},3181,"Which plastics are used in the defense industry?","\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Typically ABS/PC blend, HIPS, PMMA/ABS, PEEK, FR-ABS, PVC/ASA, PET-G, and conductive ABS are used, depending on requirements for flame resistance, strength, or EMC/ESD protection.\u003C/span>\u003C/p>",{"id":755,"title":756,"content":757},3182,"Why are plastic parts cost-efficient?","\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Tooling costs are lower than with injection molding or CNC. This makes prototypes, small series, and specialized aerospace and defense components economically feasible. See also \u003C/span>\u003Ca href=\"https://www.formary.de/en/blog/injection-molding-vs-thermoforming\">\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Injection Molding vs. Thermoforming.\u003C/span>\u003C/a>\u003C/p>",{"id":759,"title":760,"content":761},3183,"What advantages do plastic parts offer in aerospace?","\u003Cp>Plastic thermoformed parts are lightweight, robust, design-flexible, and compliant with standards. They also enable rapid iterations and cost-efficient production while maintaining high safety.\u003C/p>",{"id":763,"title":764,"content":765},3184,"Are the materials certified for the defense industry?","\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Yes. Available certifications include ISO 9001:2015, UL94 V-0, FAR 25.853 as well as project-specific test reports, material data sheets, and initial sample inspections.\u003C/span>\u003C/p>",{"id":767,"title":768,"content":769},3185,"Can prototypes and small series be produced economically?","\u003Cp>Yes. With bridge tooling and digital project management, prototypes can be produced within a few weeks, while small series can be manufactured efficiently and cost-effectively. 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use a plastic cover?","A plastic cover reliably protects components from dust, dirt, liquids, and mechanical impact. It conceals cables or electronics and ensures a clean, professional appearance.","\u003Cp>Compared to metal, plastic covers and housings are:\u003C/p>\u003Cul>\u003Cli>lighter and easier to install\u003C/li>\u003Cli>more cost-effective to manufacture, even in small quantities\u003C/li>\u003Cli>ore flexible in shape, color, and size\u003C/li>\u003Cli>impact-absorbing and noise-dampening\u003C/li>\u003Cli>resistant to chemicals and corrosion\u003C/li>\u003Cli>ESD-safe when using suitable plastics and additives\u003C/li>\u003C/ul>\u003Cp>→ Learn more in our blog: \u003Ca href=\"https://www.formary.de/en/blog/plastics-vs-metal\">Plastic vs. metal\u003C/a>\u003C/p>",{"id":2221,"title":2222,"introduction":2223,"content":2224},180,"Areas of application for plastic covers","Plastic covers are versatile and used across a wide range of industries—from mechanical engineering and medical technology to automotive and electronics applications.","\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">Medical technology: \u003C/a>housings for diagnostic devices, MRI covers, monitors, control panels\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/en/industries/mechanical-engineering\">Mechanical engineering\u003C/a> & \u003Ca href=\"https://www.formary.de/en/industries/industrial-solutions\">industry\u003C/a>: machine covers, CNC protective hoods, wheel housings, plastic enclosures\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/en/industries/thermoformed-parts-for-automotive\">Automotive \u003C/a>& caravan: interior components, wheel trims, tractor hoods, caravan covers\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/en/industries/electronics\">Electronics\u003C/a>: plastic housings with ESD protection, covers for control units, panels with cable feed-throughs\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/en/industries/agriculture-horticulture\">Agriculture & horticulture: \u003C/a>protective hoods for outdoor applications with UV resistance\u003C/li>\u003C/ul>",{"id":2226,"title":2227,"introduction":2228,"content":2229},181,"Highest Optical Quality","Plastic covers are often visible components, which is why we place special emphasis on high-quality, scratch-free surfaces.","\u003Cp>The surfaces of plastic covers can be enhanced by:\u003C/p>\u003Cul>\u003Cli>Colored plastics\u003C/li>\u003Cli>Printing or coating techniques\u003C/li>\u003Cli>Texturing\u003C/li>\u003Cli>Metallization\u003C/li>\u003Cli>Stainless steel appearance\u003C/li>\u003C/ul>\u003Cp>Compared to injection molding, thermoformed plastic covers do not show visual defects such as mold parting lines on the surface. To conceal edges or recesses, undercuts can be incorporated into the plastic enclosure.\u003C/p>",{"__component":375,"id":2231,"title":2232,"variant":484,"size":226,"introduction":85,"benefits":2233,"style":85},559,"Advantages of Plastic Covers",[2234,2238,2242,2246,2250,2254,2258,2262,2266],{"id":2235,"title":2236,"text":2237},2434,"Complex Geometries","Plastic covers allow for complex shapes and geometries to be created without high tooling costs or large initial investments.\n",{"id":2239,"title":2240,"text":2241},2435,"Cost-Effective Process","Thermoforming offers a cost-effective production method, even for small quantities of plastic covers, making it a great alternative to more expensive methods like injection molding.\n",{"id":2243,"title":2244,"text":2245},2436,"Quick Delivery","Plastic covers can be processed with a fast time-to-market, offering quicker delivery compared to injection molding.",{"id":2247,"title":2248,"text":2249},2437,"Custom Enclosures","Custom enclosures can be designed with machined cuts for openings, slots, and holes, tailored to your specific needs.\n",{"id":2251,"title":2252,"text":2253},2438,"Plastic Assemblies","Plastic covers can also integrate assembly options, such as embedding fasteners, which allows for further customization and functionality.\n",{"id":2255,"title":2256,"text":2257},2439,"Large, Stable Empty Housings","Thermoforming allows the creation of large, stable empty housings, with forming surfaces up to 3,460 x 2,260 mm.",{"id":2259,"title":2260,"text":2261},2440,"High Quality","Thermoforming offers high-quality plastic covers, with reproducibility and process security that ensures consistent results without warping.",{"id":2263,"title":2264,"text":2265},2441,"Specific Plastic Properties","The material selection for plastic covers can be optimized for specific properties, such as UV resistance, chemical resistance, and flame retardancy.",{"id":2267,"title":2268,"text":2269},2442,"Transparent or Colored","Plastic covers can be made transparent (e.g., using Plexiglas for high transparency) or colored, with the option of using colored plastic films or sheets.",{"__component":2271,"id":1733,"order":2272,"title":2273,"subtitle":2274,"text":2275,"image":2276},"page-template.text-image","text_image","Do you already have a CAD model of your thermoformed housing?","Run the thermoforming check now!","\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">Using our \u003C/span>\u003Ca href=\"https://www.formary.de/3d-services/dfm-analyse\">\u003Cspan style=\"color:rgb(0,169,165);\">DfM analysis,\u003C/span>\u003C/a>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(0,169,165);\"> \u003C/span>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">we review your CAD data for wall thickness distribution, draft angles, radii, and other criteria to ensure the technical feasibility of your thermoformed container. Simply book a free \u003C/span>\u003Ca href=\"https://meetings.hubspot.com/moritz-bittner-formary/dfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=7ebd3138-9706-4630-86b7-6d6c5cc48da5\">\u003Cspan style=\"color:rgb(0,169,165);\">demo\u003C/span> \u003C/a>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">and we’ll be happy to go through your data with you.\u003C/span>\u003C/p>",{"id":2277,"documentId":2278,"name":2279,"alternativeText":2280,"caption":16,"width":189,"height":719,"formats":2281,"hash":2325,"ext":148,"mime":151,"size":2326,"url":2327,"previewUrl":85,"provider":214,"provider_metadata":85,"createdAt":2328,"updatedAt":2328,"publishedAt":2329},2171,"e6at6lug4i30i8703pm43uta","DfM-Analyse  Mockup.png","DfM-Analyse Mockup",{"lg":2282,"md":2287,"sm":2293,"xl":2298,"2xl":2304,"avatar":2310,"default":2315,"thumbnail":2320},{"ext":148,"url":2283,"hash":2284,"mime":151,"name":2285,"path":85,"size":2286,"width":154,"height":703},"https://fsn1.your-objectstorage.com/formary-de-production-cms/lg_Df_M_Analyse_Mockup_434baf74a8.png","lg_Df_M_Analyse_Mockup_434baf74a8","lg_DfM-Analyse  Mockup.png",222.65,{"ext":148,"url":2288,"hash":2289,"mime":151,"name":2290,"path":85,"size":2291,"width":161,"height":2292},"https://fsn1.your-objectstorage.com/formary-de-production-cms/md_Df_M_Analyse_Mockup_434baf74a8.png","md_Df_M_Analyse_Mockup_434baf74a8","md_DfM-Analyse  Mockup.png",136.6,432,{"ext":148,"url":2294,"hash":2295,"mime":151,"name":2296,"path":85,"size":2297,"width":168,"height":725},"https://fsn1.your-objectstorage.com/formary-de-production-cms/sm_Df_M_Analyse_Mockup_434baf74a8.png","sm_Df_M_Analyse_Mockup_434baf74a8","sm_DfM-Analyse  Mockup.png",101.91,{"ext":148,"url":2299,"hash":2300,"mime":151,"name":2301,"path":85,"size":2302,"width":175,"height":2303},"https://fsn1.your-objectstorage.com/formary-de-production-cms/xl_Df_M_Analyse_Mockup_434baf74a8.png","xl_Df_M_Analyse_Mockup_434baf74a8","xl_DfM-Analyse  Mockup.png",318.35,720,{"ext":148,"url":2305,"hash":2306,"mime":151,"name":2307,"path":85,"size":2308,"width":182,"height":2309},"https://fsn1.your-objectstorage.com/formary-de-production-cms/2xl_Df_M_Analyse_Mockup_434baf74a8.png","2xl_Df_M_Analyse_Mockup_434baf74a8","2xl_DfM-Analyse  Mockup.png",393.21,810,{"ext":148,"url":2311,"hash":2312,"mime":151,"name":2313,"path":85,"size":1530,"width":195,"height":2314},"https://fsn1.your-objectstorage.com/formary-de-production-cms/avatar_Df_M_Analyse_Mockup_434baf74a8.png","avatar_Df_M_Analyse_Mockup_434baf74a8","avatar_DfM-Analyse  Mockup.png",70,{"ext":148,"url":2316,"hash":2317,"mime":151,"name":2318,"path":85,"size":2319,"width":202,"height":34},"https://fsn1.your-objectstorage.com/formary-de-production-cms/default_Df_M_Analyse_Mockup_434baf74a8.png","default_Df_M_Analyse_Mockup_434baf74a8","default_DfM-Analyse  Mockup.png",66.91,{"ext":148,"url":2321,"hash":2322,"mime":151,"name":2323,"path":85,"size":2324,"width":838,"height":607},"https://fsn1.your-objectstorage.com/formary-de-production-cms/thumbnail_Df_M_Analyse_Mockup_434baf74a8.png","thumbnail_Df_M_Analyse_Mockup_434baf74a8","thumbnail_DfM-Analyse  Mockup.png",26.89,"Df_M_Analyse_Mockup_434baf74a8",108.92,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Df_M_Analyse_Mockup_434baf74a8.png","2025-06-11T21:31:26.000Z","2026-01-08T22:06:29.101Z",{"__component":375,"id":1359,"title":2331,"variant":484,"size":379,"introduction":16,"benefits":2332,"style":85},"How you benefit from DfM for plastic covers",[2333,2337,2341,2345,2349,2353,2357],{"id":2334,"title":2335,"text":2336},2443,"Weight Reduction","Save material by using thinner wall thicknesses for plastic covers and housings.",{"id":2338,"title":2339,"text":2340},2444,"Cost-Effective and Better Recycling","Substitute steel or fiberglass with plastic covers to reduce costs and improve recyclability.",{"id":2342,"title":2343,"text":2344},2445,"Higher Product Quality","Scratch-free surfaces and special material properties make the plastic covers high-quality and durable.",{"id":2346,"title":2347,"text":2348},2446,"Longer Durability","Material selection ensures plastic housings and covers can withstand outdoor environments, offering extended resistance.",{"id":2350,"title":2351,"text":2352},2447,"Assembly Creation","Create plastic assemblies by incorporating connection techniques into your plastic covers, enclosures, and housings.",{"id":2354,"title":2355,"text":2356},2448,"Process Reliability","Ensure reliability and repeatability, even with large parts, thanks to our consistent manufacturing processes.",{"id":2358,"title":2359,"text":2360},2449,"Easier Cleaning","Typical features of thermoformed plastic covers make them easier to clean and maintain.",{"__component":2362,"id":2363,"title":2364,"introduction":2365,"text":2366,"variant":378,"style":2367,"cta_button":2368},"page-template.textsection",459,"Assemblies & mounting options","Upon request, we manufacture plastic covers as complete assemblies. Multiple thermoformed parts are joined by bonding, screwing, clipping, or sealing. In addition, the following options are available:","\u003Cul>\u003Cli>\u003Cstrong>Material Combinations: \u003C/strong>Incorporation of brass inserts, screws, ball pins, positioning lugs, and other fastening elements to enhance the functionality and strength of the plastic cover.\u003C/li>\u003Cli>\u003Cstrong>Cutouts: \u003C/strong>Cutouts for handles or additional modules that can be attached to the plastic housing after production, offering flexibility in design and use.\u003C/li>\u003Cli>\u003Cstrong>Premium Appearance:\u003C/strong> Sophisticated trimming techniques, such as inward-facing edges, provide a refined, high-quality look for the plastic covers, ensuring a professional and aesthetic finish.\u003C/li>\u003C/ul>",{"id":466,"background":683,"border":85},{"id":2369,"visible":228,"label":2370,"link":2371,"variant":419},882,"Learn more about assembly services","/post-processing-methods/connecting",{"__component":1536,"id":2373,"benefits_title":2374,"benefits":2375},64,"Design of plastic covers",[2376,2380,2384,2388,2392,2396],{"id":2377,"title":2378,"text":2379},223,"Radii","Radii describe the degree of edge rounding. Thermoformed plastic enclosures always require minimum radii to prevent material weakening or cracking.",{"id":2381,"title":2382,"text":2383},224,"Draft angles","Draft angles of at least approx. 3° are required for smooth demolding of a plastic cover. The exact angle depends on the material, thickness, and geometry and is defined individually by us.",{"id":2385,"title":2386,"text":2387},225,"Standards & dimensional tolerances","As standard, tolerances according to ISO 2768-m apply. If required, tighter tolerances can also be achieved—especially in connection areas that require high precision.",{"id":2389,"title":2390,"text":2391},226,"Fit accuracy","Plastic covers must fit precisely with machine interfaces or assemblies. That’s why we place particular emphasis on tolerance windows and functional interfaces.",{"id":2393,"title":2394,"text":2395},227,"Appearance & surface","Plastic covers can be designed in solid colors, with color stripes, and with smooth, grained, or textured surfaces. Logos, material markings, or date stamps can also be integrated directly.",{"id":2397,"title":2398,"text":2399},228,"Ribs & reinforcements","For short service life, we offer cost-effective lightweight solutions. For long-term use, covers are reinforced with ribs and stiffeners.",{"__component":572,"id":2401,"title":2402,"textblocks":2403},69,"Material selection for your plastic covers",[2404,2408,2412,2415],{"id":2405,"title":2406,"text":2407,"variant":580,"width":581},121,"UV resistance","For outdoor enclosures, we use UV-stable plastics. This property can be achieved through additives or by selecting materials such as ABS or ASA, which are naturally UV-resistant.",{"id":2409,"title":2410,"text":2411,"variant":580,"width":581},122,"Chemical resistance","For applications involving oils, greases, or cleaning agents, we select materials that offer long-term resistance, even in sensitive environments.",{"id":1356,"title":2413,"text":2414,"variant":580,"width":581},"Temperature resistance","In automotive or mechanical engineering applications, plastic covers often have to withstand high temperatures. We select plastics with suitable continuous operating temperatures and resistance to temperature peaks.",{"id":195,"title":2416,"text":2417,"variant":580,"width":581},"Flame retardancy","For applications with fire safety requirements, we offer UL 94–certified, flame-retardant plastics that are self-extinguishing. Ideal for medical technology, mechanical engineering, or transportation applications.",{"__component":611,"id":2419,"buttons":2420},151,[2421],{"id":2422,"visible":228,"label":2423,"link":617,"variant":225},880,"Go to the material overview",{"__component":858,"id":2425,"title":2426,"introduction":2427,"cards":2428,"style":85},533,"Product Examples of Plastic Covers","Here are several examples of thermoformed plastic covers used in various applications:",[2429,2434,2439,2444,2449,2454],{"id":2430,"title":2431,"introduction":2432,"link":70,"link_label":2433},1502,"Caravan Plastic Covers","These covers enhance both the aesthetics and protection of caravan components.","Learn more",{"id":2435,"title":2436,"introduction":2437,"link":2438,"link_label":2433},1503,"Machine Covers","Plastic machine covers are used to protect machinery from external influences.","/products/machine-covers",{"id":2440,"title":2441,"introduction":2442,"link":2443,"link_label":2433},1504,"Protective Covers for CNC Parts & Metal Components","These covers are essential in preventing contamination by dirt and particles during storage or transport.","/products/protective-covers-for-cnc-parts",{"id":2445,"title":2446,"introduction":2447,"link":2448,"link_label":2433},1505,"Tractor Plastic Covers","Tractor covers made from plastic are lightweight, enhance efficiency, and provide protection.","/products/tractor-covers",{"id":2450,"title":2451,"introduction":2452,"link":2453,"link_label":2433},1506,"Medical Technology Enclosures","Plastic enclosures are used in medical devices for diagnostics, therapy, and analysis.","/products/medical-covers",{"id":2455,"title":2456,"introduction":2457,"link":452,"link_label":2433},1507,"Electronic Plastic Enclosures","Plastic enclosures for electronics are designed to safely dissipate electrostatic charges.",{"__component":2459,"id":2460,"title":2461,"steps":2462},"page-template.project-process",22,"Project Process for Your Plastic Cover: From Inquiry to Order",[2463,2467,2471,2475,2479,2483],{"id":2464,"title":2465,"text":2466},259,"Inquiry","You configure your desired product in our configurator in the desired quantities, material and design.",{"id":2468,"title":2469,"text":2470},260,"Review & Offer","We check your data for feasibility and implementation. Then we provide you with an offer within 24 hours. At the same time, we also make suggestions for the data creation of your deep-drawn part as well as useful sampling options.",{"id":2472,"title":2473,"text":2474},261,"Data Approval","You approve our data for prototyping or the series tool.",{"id":2476,"title":2477,"text":2478},262,"Tool & Sampling","We create your tool and send you series samples for approval.",{"id":2480,"title":2481,"text":2482},263,"Series Production","After checking and approving the samples, we start manufacturing your deep-drawn parts.",{"id":2484,"title":2485,"text":2486},264,"Shipping","After completion and thorough inspection by our QA team, we will send your series delivery on its way.",{"__component":611,"id":1362,"buttons":2488},[2489],{"id":2490,"visible":228,"label":2491,"link":244,"variant":245},881,"Configure your plastic cover",{"__component":742,"id":2493,"title":2494,"variant":378,"first_accordion_open":228,"accordions":2495},477,"FAQ – Frequently asked questions about plastic covers",[2496,2499,2503,2507,2511,2515,2519,2523,2527],{"id":2497,"title":1795,"content":2498},2957,"\u003Cp>A plastic cover is a thermoformed part that protects or encloses components. It can be designed as a protective hood, plastic housing, or lid. Also available in round or rectangular shapes, transparent or colored.\u003C/p>",{"id":2500,"title":2501,"content":2502},2958,"Which plastic is suitable for housings and covers?","\u003Cp>Depending on the application: \u003Ca href=\"https://www.formary.de/en/materials/abs-plastic\">ABS \u003C/a>and \u003Ca href=\"https://www.formary.de/en/materials/asa-plastic\">ASA \u003C/a>for UV resistance, \u003Ca href=\"https://www.formary.de/en/materials/pet-a-plastic\">PET \u003C/a>for transparency, \u003Ca href=\"https://www.formary.de/en/materials/ps-plastic\">PS \u003C/a>for standard solutions, ESD materials for electronics, and UL94 flame-retardant plastics for fire protection.\u003C/p>",{"id":2504,"title":2505,"content":2506},2959,"Which post-processing options are available?","\u003Cp>Covers can be post-processed by milling, drilling, or punching to integrate openings, slots, or functional cut-outs. Learn more under\u003Ca href=\"https://www.formary.de/en/post-processing-methods/separating\"> plastic milling and punching.\u003C/a>\u003C/p>",{"id":2508,"title":2509,"content":2510},2960,"Which surface finishes are available?","\u003Cp>Smooth, grained, or textured surfaces are possible. In addition, painting, printing, or a stainless steel look can be achieved. Learn more under\u003Ca href=\"https://www.formary.de/en/post-processing-methods/surface-treatment\"> plastic surface treatment.\u003C/a>\u003C/p>\u003Cp> \u003C/p>",{"id":2512,"title":2513,"content":2514},2961,"Are plastic covers resistant to temperature and chemicals?","\u003Cp>Yes. Depending on the material, they are resistant to high temperatures, UV radiation, chemicals, and oils.\u003C/p>",{"id":2516,"title":2517,"content":2518},2962,"Are flame-retardant plastic covers available?","\u003Cp>Yes. Using UL 94–certified materials, covers can be designed to be self-extinguishing, for example for \u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">medical technology\u003C/a>, transportation, and \u003Ca href=\"https://www.formary.de/en/industries/mechanical-engineering\">mechanical engineering\u003C/a> applications.\u003C/p>",{"id":2520,"title":2521,"content":2522},2963,"Can plastic covers be manufactured as assemblies?","\u003Cp>Yes. Covers can be combined by bonding, screwing, or clipping. Inserts, ball studs, or fastening elements can also be integrated. Learn more under \u003Ca href=\"https://www.formary.de/en/post-processing-methods/connecting\">assembly services.\u003C/a>\u003C/p>",{"id":2524,"title":2525,"content":2526},2964,"What is the difference between thermoforming and injection molding?","\u003Cp>With modern thermoforming at injection-molding quality levels, complex geometries, tight tolerances, and high-quality surfaces can now be achieved cost-effectively and flexibly—even for small batch sizes. Another key advantage is that thermoforming produces smooth, homogeneous surfaces without mold parting lines, which is a clear benefit compared to injection molding. Learn more under \u003Ca href=\"https://www.formary.de/en/blog/injection-molding-vs-thermoforming\">Injection molding vs. thermoforming.\u003C/a>\u003C/p>",{"id":2528,"title":2529,"content":2530},2965,"What does Design for Manufacturing mean for plastic covers?","\u003Cp>\u003Ca href=\"https://www.formary.de/en/blog/design-for-manufacturing-guide\">Design for Manufacturing\u003C/a> (DfM) means optimizing your CAD data or designs so they can be manufactured using thermoforming in a technically feasible, cost-efficient, and process-reliable way. This includes careful consideration of radii, draft angles, wall thicknesses, and tolerances.\u003C/p>",{"__component":2532,"id":2533,"title":2534,"variant":484,"cta_button":85,"blogarticles":2535,"style":85},"page-template.blog-teaser",111,"More insights into plastic housings and covers",[2536,2545,2554,2563],{"id":2537,"documentId":2538,"createdAt":2539,"updatedAt":2540,"publishedAt":85,"locale":10,"title":2541,"introduction":2542,"content":2543,"slug":2544},358,"p7xknhhak0ukuf45xqtqknjf","2026-01-13T15:51:49.205Z","2026-01-26T08:37:46.755Z","Painting Plastic – What to Consider When Coating Thermoplastics","Painting thermoformed plastic parts is an option not only to enhance their aesthetic appeal but also to improve their durability and resistance. In this blog post, we will explore the key aspects to consider when painting thermoformed plastic parts.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Benefits of Painting Thermoformed Plastic Parts?\u003C/span>\u003C/h2>\u003Cp>There are two ways to achieve the desired \u003Ca href=\"https://www.formary.de/en/blog/surface-finishing-for-medical-housings\">surface finish\u003C/a> in thermoforming: (1) using pre-colored or pre-treated plastic sheets that already possess the necessary characteristics before the thermoforming process, or (2) post-processing the finished plastic part. The next section explains why pre-treated plastic is not always used.\u003C/p>\u003Cp>Here, we first outline the reasons and benefits of painting thermoformed plastic parts as a post-processing step:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Painting Plastic for Aesthetics and Brand Identity\u003C/span>\u003C/h3>\u003Cp>Painting your thermoformed plastic parts strengthens brand identity and enhances aesthetics. A high-quality surface immediately improves the perceived value of your product.\u003C/p>\u003Cp>You can integrate special effects such as:\u003C/p>\u003Cul>\u003Cli>High-gloss finish\u003C/li>\u003Cli>Metallic effects\u003C/li>\u003Cli>Matte or textured finishes\u003C/li>\u003C/ul>\u003Cp>Additionally, full or partial coloration, different colors, or color gradients in all RAL shades are possible.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Painting Plastic for Protection Against Environmental Influences\u003C/span>\u003C/h3>\u003Cp>A painted surface acts as a protective layer, shielding thermoformed parts from UV radiation, moisture, and chemicals. Painting plastic extends the lifespan of the parts and increases the efficiency of your production cycle.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Painting Plastic for Easier Cleaning and Maintenance\u003C/span>\u003C/h3>\u003Cp>Painted thermoformed plastic parts are easier to clean and maintain. The smooth surface prevents dirt accumulation and simplifies maintenance.\u003C/p>\u003Cp>For specific cleaning requirements, feel free to contact us directly or read our post \u003Cstrong>“How to Clean Trays.”\u003C/strong>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Painting Plastic vs. Pre-Colored Plastic Sheets – Key Reasons for Choosing Paint\u003C/span>\u003C/h2>\u003Cp>Coloring can also be achieved by purchasing pre-colored plastic sheets or films that are extruded in the desired RAL shade. However, specific circumstances and requirements may favor post-processing through painting to achieve the desired surface finish.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:19.44%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Lackiertes_Kunststoffgehaeuse_in_rot_6d1deef253.jpg\" alt=\"Kunststoff lackieren - Kunststoffgehäuse in rot\">\u003Cfigcaption>Plastic housing in orange\u003C/figcaption>\u003C/figure>\u003Cp>In the following cases, pre-colored plastic sheets are usually avoided in favor of painting thermoformed parts:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Minimum Order Quantities (MOQs)\u003C/span>\u003C/h3>\u003Cp>Custom RAL colors require custom extrusion, and most plastic manufacturers impose minimum order quantities. These quantities can be too high to justify custom extrusion for a specific product or order.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Multicolored Parts\u003C/span>\u003C/h3>\u003Cp>If a thermoformed part needs to be multicolored, it cannot be achieved with a pre-colored, extruded sheet. While simple color stripes can be added for product identification, complex color patterns require painting.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Which Plastics Can Be Painted?\u003C/span>\u003C/h3>\u003Cp>Plastics have a lower affinity for paint adhesion compared to metallic surfaces due to properties like surface energy, porosity, and smoothness. Therefore, \u003Cstrong>2K-PUR paints\u003C/strong> (two-component polyurethane-based coatings) are commonly used due to their strong adhesion and long-lasting durability.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics That Are Easy to Paint:\u003C/span>\u003C/h3>\u003Cul>\u003Cli>ABS (Acrylonitrile Butadiene Styrene)\u003C/li>\u003Cli>PC (Polycarbonate)\u003C/li>\u003Cli>PMMA (Polymethyl Methacrylate)\u003C/li>\u003Cli>PA (Polyamide)\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics That Are Difficult to Paint:\u003C/span>\u003C/h3>\u003Cul>\u003Cli>PE (Polyethylene)\u003C/li>\u003Cli>PP (Polypropylene)\u003C/li>\u003Cli>PVC (Polyvinyl Chloride)\u003C/li>\u003Cli>Other elastic plastics\u003C/li>\u003C/ul>\u003Cp>To improve paint adhesion, pre-treatment methods such as primers, adhesion promoters, or chemical treatments are often required to enhance surface energy.\u003C/p>\u003Cp>Learn more about \u003Cstrong>thermoplastic materials and their properties\u003C/strong> in our \u003Ca href=\"https://www.youtube.com/watch?v=HhU0eK7A1ag\">\u003Cstrong>Thermoplastic Plastics Webinar\u003C/strong>\u003C/a>\u003Cstrong>.\u003C/strong>\u003C/p>\u003Cp>Special pre-treatments are often carried out to improve the adhesion of coatings to plastics. This may include the use of adhesion promoters, primers, or other chemical treatments to increase the surface energy from a chemical point of view and improve adhesion.\u003C/p>\u003Cp>It is important to consider the compatibility between the plastic material and the selected coating system to ensure successful plastic coating.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Painting Plastic: The Coating Process\u003C/span>\u003C/h3>\u003Cp>Before painting, plastics require thorough pre-treatment. Various cleaning and pre-treatment methods include:\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:21.31%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoff_lackieren_Lackierverfahren_e394423dfb.jpg\" alt=\"Kunststoff lackieren - Verfahren\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Painting Plastic: The Coating Process\u003C/span>\u003C/h3>\u003Cp>Before painting, plastics require thorough pre-treatment. Various cleaning and pre-treatment methods include:\u003C/p>\u003Ch3>Surface Pre-Treatment Methods:\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>CO₂ Cleaning:\u003C/strong> Compressed carbon dioxide is used in a blasting process to remove contaminants.\u003C/li>\u003Cli>\u003Cstrong>Steam Cleaning:\u003C/strong> Hot steam cleans plastic parts without leaving residue.\u003C/li>\u003Cli>\u003Cstrong>Flame Treatment:\u003C/strong> Controlled heat application removes impurities and enhances paint adhesion.\u003C/li>\u003Cli>\u003Cstrong>Low-Pressure Plasma Treatment:\u003C/strong> Ionized gas interacts with the surface to improve adhesion without leaving residue.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Manual vs. Automated Plastic Painting\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:11.6%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Roter_Kunststoffbehaelter_Kunststoff_lackieren_65a6765195.jpg\" alt=\"Kunststoff lackieren mit roter Farbe auf der Kunststoffwanne\">\u003Cfigcaption>Red plastic container\u003C/figcaption>\u003C/figure>\u003Cp>Once the plastic parts are cleaned and pre-treated, the next step is choosing between **manual or automated painting.**Masking-free painting techniques can improve precision and efficiency.\u003C/p>\u003Cp>The choice between manual and automated painting depends on factors such as production volume, part complexity, and specific coating requirements.\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Robotic Painting:\u003C/strong> Industrial robots apply coatings precisely, ensuring uniformity on complex geometries.\u003C/li>\u003Cli>\u003Cstrong>Automated Paint Lines:\u003C/strong> Conveyor systems transport parts through the coating process for efficient high-volume production.\u003C/li>\u003Cli>\u003Cstrong>Spray Coating:\u003C/strong> Paint is atomized and applied using compressed air or electrostatics.\u003C/li>\u003Cli>\u003Cstrong>Dip Coating:\u003C/strong> Parts are submerged in paint, ensuring even coverage, followed by excess removal.\u003C/li>\u003C/ul>\u003Cp>Following the painting process, a drying phase hardens the coating, resulting in a durable, high-quality finish. These painted plastic parts are widely used in industries like \u003Cstrong>automotive, electronics, and furniture manufacturing.\u003C/strong>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Painting Plastic – A Conclusion\u003C/span>\u003C/h2>\u003Cp>Painting thermoformed plastic parts provides numerous advantages, including \u003Cstrong>aesthetic enhancement, environmental protection, and ease of maintenance.\u003C/strong> By considering material properties and using proper painting techniques, high-quality results can be achieved.\u003C/p>\u003Cp>However, \u003Cstrong>proper preparation is key.\u003C/strong> Do you have questions about the optimal color finish for your thermoformed parts? \u003Cstrong>Contact us via email or call us directly at Tel: \u003C/strong>\u003Cspan style=\"color:#005250;\">\u003Cstrong>+4971919525170\u003C/strong>\u003C/span>\u003Cstrong>.\u003C/strong>\u003C/p>","painting-plastic",{"id":2546,"documentId":2547,"createdAt":2548,"updatedAt":2549,"publishedAt":85,"locale":10,"title":2550,"introduction":2551,"content":2552,"slug":2553},341,"ijlrusckxsm6mygyyu1hkehr","2026-01-13T15:51:45.925Z","2026-01-26T08:29:40.497Z","Printing on Plastic Parts – The Difference Between Pad Printing and Screen Printing","Printing on thermoformed plastic parts enables detailed lettering, designs, and branding elements. Pad and screen printing are the most commonly used methods, depending on the application. This article explores these techniques in more detail.\n","\u003Ch2>\u003Cspan style=\"color:#005250;\">Why Print on Plastic Parts?\u003C/span>\u003C/h2>\u003Cp>Printing on plastic parts is considered an “\u003Cstrong>off-mold decoration\u003C/strong>” process, which is applied after the forming process. Especially for products such as covers, trays, and housings manufactured through \u003Cstrong>plastic deep drawing\u003C/strong>, printing is an optimal \u003Ca href=\"https://www.formary.de/en/blog/surface-finishing-for-medical-housings\">surface refinement solution\u003C/a> for customizing the appearance of deep-drawn parts.\u003C/p>\u003Cp>The print on plastic parts must not only be aesthetically appealing but also highly \u003Cstrong>durable and scratch-resistant\u003C/strong>. After all, the print—whether a logo, scales, or control elements—significantly contributes to the overall appearance of the product. Choosing the right printing process is therefore crucial.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Plastics Can Be Printed?\u003C/span>\u003C/h2>\u003Cp>You can print on:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>ABS plastic\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>PC plastic\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>PE plastic\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>PP plastic\u003C/strong>\u003C/li>\u003Cli>and more.\u003C/li>\u003C/ul>\u003Cp>Printing on plastic parts is possible with many \u003Cstrong>thermoplastics\u003C/strong>. However, it is important to note that not all plastics are equally suitable for printing.\u003C/p>\u003Cp>Some plastics have a naturally \u003Cstrong>low surface tension\u003C/strong>, making it difficult for inks to adhere. In such cases, special \u003Cstrong>pre-treatments\u003C/strong> such as cleaning, degreasing, or using adhesion promoters are recommended to improve ink adhesion.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Printing Plastic Parts with Screen Printing or Pad Printing – A Comparison\u003C/span>\u003C/h2>\u003Cp>Two of the most common methods for printing on plastic parts are \u003Cstrong>screen printing\u003C/strong> and \u003Cstrong>pad printing\u003C/strong>. Both processes have specific properties and are suitable for different applications. Which one is better for your project? Find out below:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Screen Printing on Plastic – Ideal for Printing on Flat Surfaces\u003C/span>\u003C/h3>\u003Cp>\u003Cstrong>What is screen printing?\u003C/strong>\u003C/p>\u003Cp>Screen printing is a \u003Cstrong>stencil-based process\u003C/strong> that allows precise transfer of designs onto various surfaces. It is also called \u003Cstrong>stencil printing\u003C/strong> because certain areas of the screen are covered with a stencil, allowing ink to pass through only the open sections.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:18.73%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Siebdruck_Verfahren_Grafik_c1136bba6f.png\" alt=\"Siebdruck Verfahren_Grafik\">\u003Cfigcaption>Screen printing process\u003C/figcaption>\u003C/figure>\u003Cp>Screen printing on plastic is particularly effective on flat surfaces and is often used on larger areas such as covers and housings, as the somewhat coarse textile structure limits the ability to reproduce very fine or small screen-printed motifs with precision.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Does Screen Printing Work?\u003C/span>\u003C/h3>\u003Col>\u003Cli>\u003Cstrong>Screen Preparation:\u003C/strong> A fine-mesh screen (usually made of polyester or polyamide) is stretched onto a frame. A light-sensitive coating is applied to this screen.\u003C/li>\u003Cli>\u003Cstrong>Creating the Stencil:\u003C/strong> The desired print design is transferred onto the screen through \u003Cstrong>exposure\u003C/strong>. Non-exposed areas remain ink-permeable, while exposed areas block ink.\u003C/li>\u003Cli>\u003Cstrong>Printing Process:\u003C/strong> The screen is placed on the plastic part. A squeegee (a rubber blade) spreads ink over the screen, pressing it through the open areas onto the material.\u003C/li>\u003Cli>\u003Cstrong>Drying:\u003C/strong> The printed part is dried to fix the ink, either through air drying or in specialized drying units.\u003C/li>\u003C/ol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Drucken_eines_Siebdruck_Motivs_1661271939.png\" alt=\"Drucken eines Siebdruck Motivs\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and Disadvantages of Screen Printing\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Screen Printing Advantages\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Screen Printing Disadvantages\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>High color intensity:\u003C/strong> Vibrant colors on dark materials.\u003C/td>\u003Ctd>\u003Cstrong>Complex preparation:\u003C/strong> Time-consuming and costly.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Durability:\u003C/strong> Resistant to abrasion and weather conditions.\u003C/td>\u003Ctd>\u003Cstrong>Limited detail accuracy:\u003C/strong> Fine details can be difficult to reproduce.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Special colors & effects:\u003C/strong> Metallic, fluorescent inks possible.\u003C/td>\u003Ctd>\u003Cstrong>Time-consuming multi-color printing:\u003C/strong> Each color requires a separate pass.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>High reproducibility:\u003C/strong> Ideal for large print runs.\u003C/td>\u003Ctd>\u003Cstrong>Limited flexibility:\u003C/strong> Expensive design changes.\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Pad Printing on Plastic – Ideal for Uneven and Complex Surfaces\u003C/span>\u003C/h3>\u003Cp>\u003Cstrong>What is pad printing?\u003C/strong>\u003C/p>\u003Cp>Pad printing is a \u003Cstrong>versatile and highly flexible\u003C/strong> printing process, especially suitable for \u003Cstrong>uneven and complex surfaces\u003C/strong>. It is an \u003Cstrong>indirect\u003C/strong> printing method where an \u003Cstrong>elastic silicone pad\u003C/strong> transfers the ink onto the material.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:17.42%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tampondruck_Grafik_b757f891a5.png\" alt=\"Tampondruck_Grafik\">\u003Cfigcaption>Pad Printing\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Does Pad Printing Work?\u003C/span>\u003C/h3>\u003Col>\u003Cli>\u003Cstrong>Ink Transfer:\u003C/strong> Ink is applied to an \u003Cstrong>engraved printing plate (cliché).\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Ink Pickup:\u003C/strong> A silicone \u003Cstrong>pad\u003C/strong> picks up the ink from the engraving.\u003C/li>\u003Cli>\u003Cstrong>Printing Process:\u003C/strong> The pad presses the ink onto the plastic part.\u003C/li>\u003Cli>\u003Cstrong>Adaptation to Shape:\u003C/strong> The flexible pad conforms to curved, concave, or convex surfaces.\u003C/li>\u003C/ol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tampondruck_Verfahren_20dd277708.png\" alt=\"Tampondruck Verfahren\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and Disadvantages of Pad Printing\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Pad Printing Advantages\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Pad Printing Disadvantages\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Flexible for complex shapes:\u003C/strong> Suitable for curved and irregular objects.\u003C/td>\u003Ctd>\u003Cstrong>Limited print size:\u003C/strong> More suitable for smaller areas.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Fine lines and detailed motifs:\u003C/strong> Precise reproduction of small and intricate designs.\u003C/td>\u003Ctd>\u003Cstrong>Thinner ink layer:\u003C/strong> Less intense color compared to screen printing.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>High durability:\u003C/strong> Resistant to abrasion, chemicals, and external influences.\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Efficiency:\u003C/strong> Multi-color prints possible in one step.\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Quick drying:\u003C/strong> Inks dry quickly at room temperature.\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Pad Printing vs. Screen Printing – Applications at a Glance\u003C/span>\u003C/h2>\u003Cp>The main difference between pad printing and screen printing lies in their \u003Cstrong>applications\u003C/strong> and the type of surfaces they can print on.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">When to Use Pad Printing?\u003C/span>\u003C/h3>\u003Cp>Pad printing is more \u003Cstrong>versatile\u003C/strong> when printing on \u003Cstrong>irregular and complex shapes.\u003C/strong> Specific applications include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Automotive Plastic Deep-Drawn Parts:\u003C/strong> Buttons, switches, and control knobs inside vehicles, such as \u003Cstrong>climate control dials or radio buttons.\u003C/strong> These parts often have curved or uneven surfaces, which pad printing can accurately print on.\u003C/li>\u003Cli>\u003Cstrong>Medical Plastic Deep-Drawn Parts:\u003C/strong> Used for \u003Cstrong>medical device housings\u003C/strong>, such as covers for \u003Cstrong>inhalers and dialysis machines.\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Electronic Plastic Deep-Drawn Parts:\u003C/strong> Enables \u003Cstrong>fine details\u003C/strong> such as \u003Cstrong>characters and symbols\u003C/strong> on irregular surfaces. Applications include \u003Cstrong>ESD workpiece carriers and ESD transport packaging.\u003C/strong>\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">When to Use Screen Printing?\u003C/span>\u003C/h3>\u003Cp>Screen printing is better suited for \u003Cstrong>flat and large surfaces\u003C/strong> requiring \u003Cstrong>high color density.\u003C/strong> Examples include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Plastic housings for electronics:\u003C/strong> Large casings for \u003Cstrong>household appliances, computers, and entertainment electronics.\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Large-format covers:\u003C/strong> Such as \u003Cstrong>caravan covers and tractor panels.\u003C/strong>\u003C/li>\u003C/ul>\u003Cp>The choice between pad printing and screen printing depends on the shape of the thermoformed part, the desired print quality, and the area of application.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Printing Plastic Parts with Screen Printing or Pad Printing – A Conclusion\u003C/span>\u003C/h2>\u003Cp>So, which is better – \u003Cstrong>pad printing or screen printing? Pad printing\u003C/strong> is best for \u003Cstrong>printing on uneven and complex surfaces\u003C/strong>, allowing for \u003Cstrong>highly detailed\u003C/strong> prints but with \u003Cstrong>smaller print sizes and lower color intensity.\u003C/strong>\u003C/p>\u003Cp>\u003Cstrong>Screen printing\u003C/strong> is ideal for \u003Cstrong>large and flat surfaces\u003C/strong>, offering \u003Cstrong>intense colors\u003C/strong>, but \u003Cstrong>requires more preparation and is less suitable for fine details.\u003C/strong>\u003C/p>\u003Ch4>Not sure which printing method is right for your project?\u003C/h4>\u003Cp>Contact us – we’ll be happy to assist you!\u003C/p>","printing-on-plastic-parts",{"id":2555,"documentId":2556,"createdAt":2557,"updatedAt":2558,"publishedAt":85,"locale":10,"title":2559,"introduction":2560,"content":2561,"slug":2562},349,"kry9z4d9ub1c3foldtl5lm62","2026-01-13T15:51:47.416Z","2026-01-26T08:33:46.011Z","Design for Manufacturing (DfM): Guide to Manufacturing-Oriented Design","With the new Design for Manufacturing analysis from formary, it is now possible to check CAD data for thermoformability in a matter of seconds, allowing potential sources of error to be identified early on before they become costly. Read on to find out what features the DfM software offers and what the Design for Manufacturing principle entails.","\u003Ch2>\u003Cspan style=\"background-color:rgb(255,255,255);color:#005250;\">Design for Manufacturing – The most important facts \u003C/span>\u003C/h2>\u003Cul>\u003Cli>Design for Manufacturing (DfM) means designing products so that they can be manufactured easily, economically, and with few errors.\u003C/li>\u003Cli>With a DfM analysis, you can identify manufacturing problems as early as the design phase.\u003C/li>\u003Cli>The new DfM tool by formary enables an automated analysis of your 3D models quickly, accurately, and free of charge in your browser.\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(66,66,66);\">       → Go directly to DfM Analysis:\u003C/span> \u003Ca href=\"https://www.formary.de/en/3d-services/dfm-analyse\">formary.de/en/3d-services/dfm-analyse\u003C/a>\u003C/p>\u003Chr>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is Design for Manufacturing?\u003C/span>\u003C/h3>\u003Cp>\u003Cstrong>DfM Meaning:\u003C/strong> Design for Manufacturing, Design for Manufacturability (DfM), or “manufacturing-oriented design,” refers to a design approach in which components are created in such a way that they can be produced easily, efficiently, and cost-effectively while maintaining high quality.\u003C/p>\u003Cp>In short: DfM ensures that from the design stage it is clear how the product can be manufactured later on, helping customers save both time and money.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">How does Design for Manufacturing work?\u003C/span>\u003C/h3>\u003Cp>Design for Manufacturing works by checking already during the design phase whether a component is manufacturable. There are clear manufacturing rules and criteria such as wall thicknesses, radii, or moldability:\u003C/p>\u003Col>\u003Cli>Analysis of geometry for manufacturability\u003C/li>\u003Cli>Identification of critical areas (e.g., overly thin wall sections)\u003C/li>\u003Cli>Adjusting the design for optimization\u003C/li>\u003Cli>Validation and release for the manufacturing process\u003C/li>\u003C/ol>\u003Ch3>\u003Cspan style=\"color:#005250;\">The 5 Design for Manufacturing Principles\u003C/span>\u003C/h3>\u003Cp>Design for Manufacturing is based on five key principles that help solve manufacturing issues early in the design phase.\u003C/p>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Design for Manufacturing Principle\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Application in the Development Process\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Problems Solved by DfM\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>1️⃣ Error prevention in design\u003C/strong>\u003C/td>\u003Ctd>Identify and eliminate potential error sources early\u003C/td>\u003Ctd>Fewer complaints, higher quality\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>2️⃣ Manufacturing-oriented design\u003C/strong>\u003C/td>\u003Ctd>Consider appropriate processes and materials\u003C/td>\u003Ctd>Improved manufacturability, reduced production costs\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>3️⃣ Reducing the number of parts\u003C/strong>\u003C/td>\u003Ctd>Design with as few individual parts as possible\u003C/td>\u003Ctd>Less assembly effort, fewer error sources\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>4️⃣ Standardized components\u003C/strong>\u003C/td>\u003Ctd>Use standard parts instead of custom-made ones\u003C/td>\u003Ctd>Shorter lead times, lower costs, easier sourcing\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>5️⃣ Modularization of design\u003C/strong>\u003C/td>\u003Ctd>Divide components into interchangeable modules\u003C/td>\u003Ctd>Better maintainability, easier variant production\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of Design for Manufacturing\u003C/span>\u003C/h2>\u003Cp>Thanks to its core principles, DfM analysis offers numerous benefits:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Early error detection:\u003C/strong> Critical areas are identified directly in the CAD model\u003C/li>\u003Cli>\u003Cstrong>Cost reduction:\u003C/strong> Avoidance of expensive rework and complaints\u003C/li>\u003Cli>\u003Cstrong>More efficient processes:\u003C/strong> Fewer queries and delays during development\u003C/li>\u003Cli>\u003Cstrong>Improved quality:\u003C/strong> Better feasibility and reproducibility in series production\u003C/li>\u003Cli>\u003Cstrong>Planning reliability:\u003C/strong> Clear communication with manufacturing and tooling departments\u003C/li>\u003Cli>\u003Cstrong>Adaptable to different manufacturing processes:\u003C/strong> Whether injection molding, 3D printing, or \u003Ca href=\"https://www.formary.de/en/plastic-thermoforming\">vacuum forming,\u003C/a> DfM supports all common manufacturing methods.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">What Does DfM Analysis Mean for the Thermoforming Process in Practice?\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffabdeckung_ac9d53be5c.png\" alt=\"Plastic cover in orange\">\u003C/figure>\u003Cp>When designing a plastic thermoformed parts such as \u003Ca href=\"https://www.formary.de/en/solutions/plastic-covers\">plastic covers\u003C/a> or \u003Ca href=\"https://www.formary.de/en/solutions/plastic-containers\">plastic containers,\u003C/a> this means, for example:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Optimizing wall thicknesses\u003C/strong> to ensure even material distribution\u003C/li>\u003Cli>\u003Cstrong>Designing radii\u003C/strong> so that they can be thermoformed without issues\u003C/li>\u003Cli>\u003Cstrong>Building components modularly\u003C/strong> to allow for product variants\u003C/li>\u003Cli>\u003Cstrong>Using standardized mounts or fasteners\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Considering draft angles\u003C/strong> to enable easy removal from the mold\u003C/li>\u003C/ul>\u003Cdiv class=\"raw-html-embed\">\n    \u003Cstyle>\n    .c-container {\n            border: 2px solid #15A9A4;\n            padding: 10px;\n            margin: 10px;\n            border-radius: 10px;\n        }\n\n    .c-container {\n            margin: 0;\n        }\n    \u003C/style>\n\n\u003Cdiv class=\"c-container\">       \n\u003Cp>ℹ️ For more details on what you need to consider when designing plastic thermoformed parts, see our article on \u003Ca href=\"https://www.formary.de/en/blog/design-guidelines-for-thermoformed-parts\"> Design Guidelines for Plastic Thermoformed Parts.\u003C/a> \u003C/p>\n    \u003C/div>\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Challenges and Disadvantages of DfM?\u003C/span>\u003C/h2>\u003Cp>Although Design for Manufacturing offers many benefits, there are typical challenges in practice:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Often requires extensive experience:\u003C/strong> Designers must consider complex manufacturing rules\u003C/li>\u003Cli>\u003Cstrong>Time-consuming manual checks:\u003C/strong> Without software tools, wall thicknesses, radii, and draft angles must be analyzed manually\u003C/li>\u003Cli>\u003Cstrong>Risk of errors:\u003C/strong> Human judgment is error-prone and can lead to costly rework\u003C/li>\u003Cli>\u003Cstrong>Communication problems:\u003C/strong> Without clear visualization, misunderstandings can occur between design and tooling departments\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Solution: DfM Analysis of Plastic Thermoformed Parts in Seconds\u003C/span>\u003C/h2>\u003Cp>Upload your thermoforming part data, and our DfM software will evaluate whether it can be manufactured as designed, or which geometries need to be modified for technical, functional, or cost-related reasons. These modifications can then be carried out either by you or by us.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Df_M_Analyse_Mockup_434baf74a8.png\" alt=\"DfM-Analysis Mockup\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Does the DfM Analysis Work?\u003C/span>\u003C/h3>\u003Col>\u003Cli>Upload STEP file\u003C/li>\u003Cli>Automatic analysis in about 60 seconds\u003C/li>\u003Cli>Color-coded results for:\u003Cul>\u003Cli>Wall thickness distribution\u003C/li>\u003Cli>Radii\u003C/li>\u003Cli>Edges and draft angles\u003C/li>\u003Cli>Stretching ratio\u003C/li>\u003Cli>Narrow sections and details\u003C/li>\u003C/ul>\u003C/li>\u003C/ol>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Df_M_Analyse_Funktionen_4592bb4112.png\" alt=\"DfM-Analyse Funktionen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of the DfM Tool\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Automated analysis in seconds\u003C/li>\u003Cli>Color-coded and visually intuitive\u003C/li>\u003Cli>No waiting times or manual queries\u003C/li>\u003Cli>Detect errors early and reduce costs\u003C/li>\u003Cli>Usable directly in the browser\u003C/li>\u003Cli>No expert knowledge required\u003C/li>\u003Cli>Provides a basis for smooth coordination with toolmaking\u003C/li>\u003C/ul>\u003Cp>ℹ️ For more details about the DfM analysis, visit: \u003Ca href=\"https://www.formary.de/en/3d-services/dfm-analyse\">formary.de/en/3d-services/dfm-analyse\u003C/a>\u003C/p>\u003Chr>\u003Ch3>\u003Cspan style=\"color:#005250;\">Frequently Asked Questions About the DfM Analysis\u003C/span>\u003C/h3>\u003Ch4>What is Design for Manufacturing?\u003C/h4>\u003Cp>Design for Manufacturing (DfM) means designing products so they can be manufactured efficiently, cost-effectively, and without errors. The goal is to consider all manufacturing aspects right from the design stage.\u003C/p>\u003Ch4>What does DfM mean?\u003C/h4>\u003Cp>DfM stands for “Design for Manufacturing” and describes a design approach that optimizes manufacturability and production costs from the very beginning.\u003C/p>\u003Ch4>How much does the DfM analysis cost?\u003C/h4>\u003Cp>The use of our tool is free of charge.\u003C/p>\u003Ch4>Which formats does the tool support?\u003C/h4>\u003Cp>Currently: .STEP files for 3D CAD models.\u003C/p>\u003Ch4>Who is the analysis suitable for?\u003C/h4>\u003Cp>Designers, engineers, and companies aiming to manufacture thermoformed parts efficiently and reliably.\u003C/p>\u003Ch4>How long does the DfM analysis take?\u003C/h4>\u003Cp>The analysis usually takes less than a minute, depending on model complexity.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Design for Manufacturing for Plastic Thermoformed Parts – Now Easier Than Ever\u003C/span>\u003C/h2>\u003Cp>Design for Manufacturing ensures that your products are manufacturable right from the start. With our free DfM analysis, you can check your design in about 60 seconds—for fewer errors, lower costs, and smoother workflows.\u003C/p>\u003Cp>→ Book your \u003Ca href=\"https://meetings.hubspot.com/moritz-bittner-formary/dfm-analyse-demo?utm_source=landingpage&utm_medium=demo-button&utm_campaign=dfm-analyse&uuid=69376d09-d796-4f3c-9d5e-ff6833d70b23\">demo \u003C/a>now!\u003C/p>","design-for-manufacturing-guide",{"id":2564,"documentId":2565,"createdAt":2566,"updatedAt":2567,"publishedAt":85,"locale":10,"title":2568,"introduction":2569,"content":2570,"slug":2571},355,"nz5g6k8re0g3v1tfg9e9ppvl","2026-01-13T15:51:48.617Z","2026-01-26T08:36:28.367Z"," Design Guidelines for Plastic Thermoformed Parts – Top 13 Tips for Plastic-Optimized Construction","Plastic thermoforming is shaped by factors like material quality, temperature, pressure, speed, and tool geometry. With the right design principles, you can prevent errors in CAD and production. Formary has gathered key tips to help you optimize your thermoformed parts.\n","\u003Ch2>\u003Cspan style=\"color:#005250;\">1. Design Rule: Radii in Plastic Thermoforming\u003C/span>\u003C/h2>\u003Cp>When designing plastic parts, it is essential to incorporate the largest possible radii to facilitate material stretching. Thermoformed parts should always have a minimum radius of 1.5 mm. On the tooling side, a minimum radius is required, which, as a rough rule of thumb (since it depends on many factors), should not be smaller than the initial material thickness.\u003C/p>\u003Cp>If sharp edges are necessary, ensure that the radius is at least equal to the starting material thickness. If the radius is smaller, forming the part becomes difficult or even impossible, increasing costs due to longer tool machining times.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_801d30d937.png\" alt=\"Radii in Plastic Thermoforming\">\u003C/figure>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>\n.c-container {\nborder: 2px solid #15A9A4;\npadding: 10px;\nmargin: 10px;\nborder-radius: 10px;\n}\n\n.c-container {\nmargin: 0;\n}\n\u003C/style>\n\n\u003Cdiv class=\"c-container\"> \n\u003Cp> \u003Cb>Caution:\u003C/b> The radii are shown larger on the deep-drawn part than on the tool itself. For both positive and negative tools, when the specified radii are as small as possible, it is particularly important to ensure that the material fits as tightly as possible into the corners. The radius on the side facing away from the tool is determined by the radius of the tool side, the material type, the material elongation, and the material thickness. \n\u003C/p>\n\u003C/div>\n\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">2. Design Rule: Draft Angles\u003C/span>\u003C/h2>\u003Cp>The angle between the vertical component wall and the demolding direction is called the \u003Cstrong>draft angle\u003C/strong>. Since draft angles affect the final shape of the thermoformed part, they must be incorporated early in the CAD model.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_45961b91ba.png\" alt=\"Draft Angles\">\u003C/figure>\u003Cp>Design vertical walls with draft angles to ensure easy demolding without visible surface defects.\u003C/p>\u003Cp>ℹ️ \u003Cstrong>Recommended Draft Angles:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>General recommendation: >2°\u003C/li>\u003Cli>Industry standard for negative molds: 1.5 - 2°\u003C/li>\u003Cli>Industry standard for positive molds: 4 - 6°\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">3. Design Rule: Forming Ratio and Wall Thickness\u003C/span>\u003C/h2>\u003Cp>The forming ratio describes the relationship between the height and width of the formed area. Since the material is stretched into the mold, it becomes thinner during the process. The forming ratio depends on the tool geometry and final part shape.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.06%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Umformverhaetlnis_bei_der_Konstruktion_von_Tiefziehteilen_65263b290b.png\" alt=\"Umformverhätlnis bei der Konstruktion von Tiefziehteilen\">\u003C/figure>\u003Cp>The resulting wall thickness can be roughly calculated using the following formula:\u003C/p>\u003Cp>\u003Cstrong>d₂ = (F₁ / F₂) × d₁\u003C/strong>\u003C/p>\u003Cp>Where:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>F₁\u003C/strong> = Area of the material blank (excluding clamping edge)\u003C/li>\u003Cli>\u003Cstrong>F₂\u003C/strong> = Surface area of the final thermoformed part\u003C/li>\u003Cli>\u003Cstrong>d₁\u003C/strong> = Initial material thickness\u003C/li>\u003Cli>\u003Cstrong>d₂\u003C/strong> = Final wall thickness\u003C/li>\u003C/ul>\u003Cp>ℹ️ More details on radii, draft angles, and forming ratios can be found in the tolerances section.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">4. Design Rule: Positive vs. Negative Forming and Wall Thickness\u003C/span>\u003C/h2>\u003Cp>The deeper the material is stretched during thermoforming, the thinner the remaining wall thickness. Typically, the desired wall thickness is determined first, and then the required starting material thickness is calculated (reverse engineering).\u003C/p>\u003Cp>The stretching ratio describes the change in material length from its initial thickness to the final thermoformed part. In general:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Positive forming\u003C/strong> results in a lower and more favorable stretch ratio compared to negative forming.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_902be0c5b9.png\" alt=\"Negative Forming\">\u003C/figure>\u003Cp>Due to the viscoelastic behavior of thermoplastics during stretching, there are a few rules of thumb to keep in mind during the molding process when designing plastic parts: \u003C/p>\u003Cul>\u003Cli>The colder the semi-finished product during stretching, the greater the force required to stretch it.\u003C/li>\u003Cli>The faster the deformation speed, the greater the force required to stretch it.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_d0fda1fcc0.png\" alt=\"Negative formed mold vs positive shaped mold\">\u003C/figure>\u003Cp>In negatively molded parts, the weak point of the deep-drawn part is therefore in the bottom area after forming, as material is stretched from the edge into the bottom of the mold cavity. This causes the material to thin out. In positively molded parts, the weak point of the deep-drawn part is at the edge, as the material first touches the positive mold at the bottom of the future deep-drawn part and thins out the edge area. Excessively thin initial thicknesses and a poor forming ratio, i.e., the ratio of opening width to opening depth, further exacerbate the negative effect.\u003C/p>\u003Ch2>5. Design Rule: Material Stretching in Cavities\u003C/h2>\u003Cp>For negative-formed cavities, the \u003Cstrong>depth-to-width ratio should not exceed 1.5:1\u003C/strong>. A greater depth results in significant thinning, increasing the risk of rupture at the bottom edges.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:27.29%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Materialverstreckung_bei_der_Konstruktion_von_Tiefziehteilen_8ae1a4a0ac.png\" alt=\"Materialverstreckung bei der Konstruktion von Tiefziehteilen\">\u003C/figure>\u003Cp>The table explains the possibilities of different pull ratios for negative and positive shapes:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Forming Ratios for Negative and Positive Forms\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Depth-to-Width Ratio\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Positive Forming\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Negative Forming\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>0.3:1\u003C/td>\u003Ctd>Possible\u003C/td>\u003Ctd>Possible\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>0.5:1\u003C/td>\u003Ctd>Possible\u003C/td>\u003Ctd>Needs punch assistance\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>1:1\u003C/td>\u003Ctd>Possible\u003C/td>\u003Ctd>Needs punch assistance\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>1.5:1\u003C/td>\u003Ctd>Material distortion at the limit\u003C/td>\u003Ctd>Material distortion at the limit\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>2:1\u003C/td>\u003Ctd>Must be tested; cannot be simulated\u003C/td>\u003Ctd>Must be tested; cannot be simulated\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">6. Design Rule: Transition Contours\u003C/span>\u003C/h2>\u003Cp>As mentioned before, small radii should be avoided in thermoforming. Particularly in \u003Cstrong>precise cavity shapes\u003C/strong>, slightly rounded contours improve formability while maintaining full functionality.\u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:25%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_1c82cbace3.png\" alt=\"Transition Contours\">\u003C/figure>\u003Cp>Figure 1 shows a cavity contour that is difficult to deep draw, while Figure 2 shows a modified contour that can be formed easily. Modifying the draft angles and radii makes the deep-drawn part easier to draw, which improves quality. This also minimizes the risk of tearing and guarantees higher reproducibility.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_a0fcbf36e7.png\" alt=\"Undercuts\">\u003C/figure>\u003Cp>Finally, cycle times are also shorter, which results in a generally more favorable unit price. Transitions from edge contours or stepped areas can also be smoothed out by beveling.\u003C/p>\u003Cp>If the radii are too small, there is always a risk of wrinkling during deep drawing, especially with positive molding. To avoid wrinkles, rib-shaped transitions can also be used in plastic design to at least form a wrinkle in a targeted manner during positive deep drawing.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">7. Design Rule: Undercuts\u003C/span>\u003C/h2>\u003Cp>Undercut contours represent geometries in the mold that prevent the part from being separated smoothly from the mold. Since, unlike in injection molding, the mold in thermoforming does not consist of two halves, undercuts are generally more difficult to demold. As undercut geometries complicate demolding, they should be avoided as far as possible during design.\u003C/p>\u003Cp>This is easier said than done: undercuts play a key role in many deep-drawn parts, as they are used in the form of stacking elements and clamps. Therefore, undercut contours are often unavoidable. For this reason, when designing plastic parts, it is important to reduce them to a level that can be deep-drawn.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">8. Design Rule: Shrinkage During Processing\u003C/span>\u003C/h2>\u003Cp>Remember that the processing shrinkage of a plastic thermoformed part is an important factor that influences the final size and shape. After demolding, the part shrinks further due to the material behavior. This shrinkage varies depending on the material and can continue for up to 24 hours after the part has cooled down. In the case of semi-crystalline thermoplastics in particular, post-shrinkage never stops and the part can continue to shrink over time.\u003C/p>\u003Cp>To take this into account, the design of the deep-drawing tool should calculate and plan for shrinkage in advance and design the size and geometries of the tool accordingly.\u003C/p>\u003Cp>Important factors that influence shrinkage are the \u003Ci>selected plastic\u003C/i> and the demolding temperature, which can be controlled by the processor. However, keep in mind that the extrusion of the material also plays a role and internal stresses in the semi-finished product must be taken into account when designing plastic parts. A sample test should therefore be carried out before production begins in order to identify potential problems such as shrinkage at an early stage.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">9. Design Rule: Thermoformable Tolerances\u003C/span>\u003C/h2>\u003Cp>Deep-drawn parts are designed for most industrial and packaging applications with a tolerance of +/- ~1 mm. This corresponds to the tolerance range according to ISO 2768-c for the 120 to 400 mm length dimensions commonly used in this product area.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_fb44b4374a.png\" alt=\"Thermoformable Tolerances\">\u003C/figure>\u003Cp>Forming tighter tolerances usually involves additional costs. These are due to longer demolding times, greater manufacturing costs, and/or longer cycle times.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">10. Design Rule: Fastening Points in Assemblies\u003C/span>\u003C/h2>\u003Cp>Fixing points are required to assemble various deep-drawn parts or assemblies. Many fastening technology options are used to securely close deep-drawn parts. These must be carefully considered from the outset to ensure that the design is suitable for plastics. Depending on the mechanical load, the frequency of opening and closing, and the stability of the connection, various options are available for achieving a force-fit connection.\u003C/p>\u003Cp>In permanently force-fit connections, screws or rivets are often attached to the deep-drawn parts at the transition points between two parts in order to achieve a connection.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_52b2fb3969.png\" alt=\"Fastening Points in Assemblies\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">11. Design Rule: Stacking Design\u003C/span>\u003C/h2>\u003Cp>If your deep-drawn part is to be stacked, this must be taken into account at an early stage of the design process so that space is left for stacking. Various factors determine the selection of the appropriate stacking technique:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Initial material thickness\u003C/span>\u003C/h3>\u003Cp>The choice of stacking for a thermoformed part depends primarily on the rigidity of the thermoformed part and the sliding properties of the material. The thicker the material (often the case with reusable trays), the better it can be stacked. The poorer the sliding properties of the material, the better the static friction and the better it can be stacked.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensitivity of the products\u003C/span>\u003C/h3>\u003Cp>If the components cannot (or should not) be stacked on top of each other, but a few millimeters of air must be maintained, a higher-quality stacking technique is required. The reason for this is that the stacking of the deep-drawn part is self-supporting, i.e., the weight of the trays and their contents must be supported on the tray surface without additional supports.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Urgency of the schedule\u003C/span>\u003C/h3>\u003Cp>Complex stacking techniques with movable stacking elements require production using a flap tool. The manufacture of such a tool is more time-consuming than a relatively simple undercut stacking tool.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">12. Design rule for thermoformed plastic parts: Material selection\u003C/span>\u003C/h2>\u003Cp>Softer plastics exhibit \u003Cstrong>greater deformation\u003C/strong> and higher processing shrinkage after demolding. Materials with high hardness and rigidity are automatically in a better tolerance group in terms of accuracy.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">13. Additional tip: Optimally positioned engravings\u003C/span>\u003C/h2>\u003Cp>If you require markings on the thermoformed part, these can be engraved directly into the mold. The cost of engraving can vary greatly depending on how it is applied. As a rule of thumb, negative (recessed) engraving is relatively inexpensive, while positive (raised) engraving is significantly more complex and therefore more expensive.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Designing plastic parts – it's easy with our design tips\u003C/span>\u003C/h2>\u003Cp>By observing these basic design rules, potential sources of error in the end product can be identified and proactively avoided as early as the CAD data creation stage. This allows you to move straight from your product to prototyping.\u003C/p>\u003Cp>Do you have any further questions? Then get in touch with us or download our design guide for more information on plastic thermoforming.\u003C/p>","design-guidelines-for-thermoformed-parts",{"__component":2573,"id":5,"title":2574,"employee":2575},"page-template.schedule-a-call","Do you have any questions about plastic covers? Schedule a consultation",{"id":902,"documentId":2576,"createdAt":2577,"updatedAt":2578,"publishedAt":85,"locale":10,"role":2579,"name":2580,"email":2581,"phone":2582,"meeting_url":2583},"g1eeasqp15jxaye52a997fbs","2026-01-16T11:11:54.168Z","2026-01-26T16:15:12.944Z","Co-Founder","Moritz Bittner","moritz.bittner@formary.de","+49 7191 9525172","https://meetings.hubspot.com/moritz-bittner",{"__component":873,"id":2585,"title":2586,"link":244,"cta_label":876,"cta_note":2587},368,"Configure Your Plastic Cover with formary.","Get your non-binding offer for your plastic cover today.",{"__component":879,"id":2589,"title":881},407,[2591],{"id":2592,"documentId":1749,"createdAt":2593,"updatedAt":2594,"publishedAt":85,"locale":128,"slug":2595,"name":2596},14,"2026-01-08T23:05:34.389Z","2026-01-26T07:52:57.932Z","kunststoff-abdeckungen-gehaeuse","Abdeckungen & Gehäuse",[2598],{"id":2599,"documentId":1227,"createdAt":2600,"updatedAt":2601,"publishedAt":85,"locale":128,"name":1548,"slug":2602,"description":2603},2,"2026-01-08T23:05:54.886Z","2026-01-25T22:51:55.242Z","kunststoffgehaeuse-fuer-elektronik-elektronikgehaeuse-kunststoff","Elektronik Kunststoffgehäuse für elektronische Bauteile zum Schutz vor Staub, Feuchtigkeit, mechanischen Schäden und elektromagnetischer Strahlung",[2605],{"id":2606,"documentId":133,"createdAt":2607,"updatedAt":2608,"publishedAt":85,"locale":128,"name":2609,"slug":2610,"description":2611},28,"2026-01-08T23:03:44.650Z","2026-01-25T21:53:48.902Z","Luftfahrt & Verteidigung","luftfahrt-verteidigung","Leichtbau, Präzision und hohe Beständigkeit für A&D-Anwendungen",{}]