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To ensure fast turnaround times, we use cost-effective 3D-printed tools, Ureol tools, and segmented tools for rapid prototype tooling.",[233],{"id":234,"visible":224,"label":235,"link":236,"variant":237},734,"Get your offer","/configurator","secondary",{"__component":239,"id":240,"title":241,"variant":242,"size":243,"introduction":85,"benefits":244,"style":293},"page-template.benefits",482,"Advantages of Prototypes in Thermoforming","horizontal","normal",[245,263,278],{"id":246,"title":247,"text":248,"icon":249},2066,"Time Savings","Prototype tools can be quickly and directly manufactured from digital models, ensuring high efficiency in development.",{"id":250,"documentId":251,"name":252,"alternativeText":253,"caption":16,"width":254,"height":254,"formats":85,"hash":255,"ext":256,"mime":257,"size":258,"url":259,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":260,"updatedAt":261,"publishedAt":262},49,"gxg5fbb5eldkzmvlu47xbohe","Zeit_Icon","Zeit und Aufwand sparen_Schnelle Abwicklung_Icon",48,"times_5268ebcf86",".svg","image/svg+xml",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":264,"title":265,"text":266,"icon":267},2067,"Reduced Investment Risk","Early-stage testing helps detect and fix potential design flaws, reducing costly errors in mass production.",{"id":268,"documentId":269,"name":270,"alternativeText":271,"caption":16,"width":254,"height":254,"formats":85,"hash":272,"ext":256,"mime":257,"size":273,"url":274,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":275,"updatedAt":276,"publishedAt":277},948,"wjkzqbpxuf6fvq3wi0sliq7d","Geld_Icon.svg","Geld_Icon","Geld_Icon_aa91560366",0.81,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Geld_Icon_aa91560366.svg","2024-03-01T17:12:21.000Z","2024-05-14T15:06:47.000Z","2026-01-08T22:03:45.159Z",{"id":279,"title":280,"text":281,"icon":282},2068,"Continuous Optimization","Prototypes undergo iterative improvements to meet functional and quality standards before full-scale production.",{"id":283,"documentId":284,"name":285,"alternativeText":286,"caption":16,"width":254,"height":254,"formats":85,"hash":287,"ext":256,"mime":257,"size":288,"url":289,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":290,"updatedAt":291,"publishedAt":292},188,"yw2btz2rlmjwt8lymalpsnal","chart-bar.svg","Erhöhte Effizienz_Diagramm Icon","chart_bar_f4c8ca22dc",0.59,"https://fsn1.your-objectstorage.com/formary-de-production-cms/chart_bar_f4c8ca22dc.svg","2021-07-06T11:12:57.000Z","2023-09-26T17:53:41.000Z","2026-01-08T22:02:03.285Z",{"id":294,"background":295,"border":85},835,"primary",{"__component":297,"id":298,"order":299,"title":300,"subtitle":301,"text":302,"image":303},"page-template.text-image",182,"text_image","What does Prototype Construction for Thermoformed Plastic Parts Involve?","Prototype development for thermoformed parts involves creating functional prototype tools.","\u003Cp>Since forming plastic requires precision-engineered molds, each new product requires a custom toolset. Once produced, thermoforming tools offer long service life and can be used for multiple production runs.\u003C/p>",{"id":142,"documentId":143,"name":144,"alternativeText":145,"caption":85,"width":146,"height":147,"formats":304,"hash":206,"ext":150,"mime":153,"size":207,"url":208,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":210,"updatedAt":211,"publishedAt":212},{"lg":305,"md":306,"sm":307,"xl":308,"2xl":309,"avatar":310,"default":311,"thumbnail":312},{"ext":150,"url":151,"hash":152,"mime":153,"name":154,"path":85,"size":155,"width":156,"height":157},{"ext":150,"url":159,"hash":160,"mime":153,"name":161,"path":85,"size":162,"width":163,"height":164},{"ext":150,"url":166,"hash":167,"mime":153,"name":168,"path":85,"size":169,"width":170,"height":78},{"ext":150,"url":172,"hash":173,"mime":153,"name":174,"path":85,"size":175,"width":176,"height":177},{"ext":150,"url":179,"hash":180,"mime":153,"name":181,"path":85,"size":182,"width":183,"height":184},{"ext":150,"url":186,"hash":187,"mime":153,"name":188,"path":85,"size":189,"width":190,"height":191},{"ext":150,"url":193,"hash":194,"mime":153,"name":195,"path":85,"size":196,"width":197,"height":198},{"ext":150,"url":200,"hash":201,"mime":153,"name":202,"path":85,"size":203,"width":204,"height":205},{"__component":314,"id":315,"title":316,"introduction":317,"text":318,"variant":242,"style":85,"cta_button":85},"page-template.textsection",434,"Prototype Tool vs. Series Tool in Thermoforming","In thermoforming, there are differences between prototype tools and series tools in the materials from which they are made.","\u003Ch4>Prototype Tool\u003C/h4>\u003Cul>\u003Cli>\u003Cstrong>Purpose: \u003C/strong>Used for producing prototype plastic parts.\u003C/li>\u003Cli>\u003Cstrong>Features:\u003C/strong> In plastic thermoforming, prototype tools are often easier and faster to produce than series tools. They can be made from less cost-intensive materials and are designed to enable quick adjustments and changes to the design.\u003C/li>\u003Cli>\u003Cstrong>Lifespan:\u003C/strong> The service life of a prototype tool is generally limited, as it is used for the early development stages of the deep-drawn part and is not designed for long-term series production.\u003C/li>\u003C/ul>\u003Ch4>Series Tool\u003C/h4>\u003Cul>\u003Cli>\u003Cstrong>Purpose: \u003C/strong>A series tool is used to produce large quantities of parts or products in series production.\u003C/li>\u003Cli>\u003Cstrong>Features: \u003C/strong>Series tools for plastic deep-drawn parts are highly precise and robust. They are made from high-quality materials such as aluminum that can withstand the demands of series production. 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Due to the high temperatures and stresses involved in thermoforming, these tools are typically suited for producing a limited number of prototypes.\u003C/p>","\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Applications of 3D-Printed Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Testing form-fit accuracy\u003C/li>\u003Cli>Small batch samples: Max. 1-3 pieces\u003C/li>\u003Cli>Rapid prototyping\u003C/li>\u003Cli>Lead time: Approx. 3-5 business days\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Advantages of 3D-Printed Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Cost-Effective: Affordable solution depending on size & printing method\u003C/li>\u003Cli>Speed: Enables fast fit testing, especially for tray molds\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Limitations of 3D-Printed Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Accuracy: Material distribution in thermoformed parts may not be precisely replicated\u003C/li>\u003Cli>Material Selection: Certain plastics, like PP, require temperature-controlled series tools for optimal forming\u003C/li>\u003C/ul>",[],{"id":407,"title":408,"text":409,"sidebar_information":410,"image":85,"buttons":411},504,"Prototyping with Ureol Sample Tools","\u003Cp>Ureol is a modeling block material used for prototype tooling in thermoforming. It allows for the creation of partial or full-scale prototypes that closely resemble final thermoformed parts produced with aluminum tools.\u003C/p>\u003Cp>While milling times for Ureol tools are similar to those of aluminum, Ureol itself is a more cost-effective material. However, due to its lower heat and pressure resistance, only a limited number of samples can be produced.\u003C/p>","\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Applications of Ureol Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Enhanced fit testing (milled rather than printed for higher accuracy)\u003C/li>\u003Cli>Small batch samples: 3-10 pieces\u003C/li>\u003Cli>Lead time: 1-2 weeks\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Advantages of Ureol Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Near-production quality: Samples are close to final series parts, with minor deviations\u003C/li>\u003Cli>Cost savings: Only 20-30% of the price of a full-scale aluminum tool\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Limitations of Ureol Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Additional costs: Acts as an intermediate step before the final production tool\u003C/li>\u003Cli>Extended lead time: Series tooling starts only after prototype approval, adding 2-3 weeks to the project timeline\u003C/li>\u003Cli>Ideal for high-accuracy prototyping before investing in full-scale series tooling!\u003C/li>\u003C/ul>",[],{"id":413,"title":414,"text":415,"sidebar_information":416,"image":85,"buttons":417},505,"Prototyping with Partial-Series Aluminum Tools","\u003Cp>A partial-series aluminum tool is an advanced prototype solution that replicates final production results with high accuracy. It offers cost savings by using a single-cavity tool instead of a multi-cavity series mold.\u003C/p>\u003Cp>\u003Cstrong>Important:\u003C/strong> This prototype tool is a preliminary step before full-series aluminum tooling, so additional lead time must be factored into the project timeline.\u003C/p>","\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Applications of Partial-Series Aluminum Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Optimized fit testing under production-like conditions (heat control, setup)\u003C/li>\u003Cli>Analysis of forming properties, material stretching, and tolerance windows\u003C/li>\u003Cli>Lead time: 2-3 weeks\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Advantages of Partial-Series Aluminum Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:hsl(0, 0%, 100%);\">Production-grade quality: Captures final contours with high precision\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:hsl(0, 0%, 100%);\">Cost savings: A fraction of the price of a full-scale production tool\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:hsl(0, 0%, 100%);\">Expandable design: The tool can be converted into a full production mold after approval\u003C/span>\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Limitations of Partial-Series Aluminum Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Extended lead time: Adds 2-3 weeks to the overall project timeline, as series tooling starts only after approval\u003C/span>\u003C/li>\u003C/ul>",[],{"id":419,"title":420,"text":421,"sidebar_information":422,"image":85,"buttons":423},506,"Prototyping with Full-Scale Production Tools","\u003Cp>A full-series aluminum tool is used for both prototyping and mass production. The prototype thermoformed parts are produced under optimized stretching, heat, and cooling conditions, ensuring final production quality from the outset.\u003C/p>\u003Cp>For mid-to-high volume production, multi-cavity tools are commonly used to improve output efficiency and reduce per-unit costs.\u003C/p>","\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Applications of Full-Series Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Small, medium, and high-volume production (from a few hundred to millions of parts)\u003C/span>\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Advantages of Full-Series Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">True production quality: Prototypes are identical to final series parts\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">No extra tooling costs: Prototyping is included in the series tool price\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Samples are (usually) included in the series tool price\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Faster transition to production: No additional approval loops needed before full production\u003C/span>\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:rgb(12,12,12);\">Limitations of Full-Series Prototype Tools\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Potential rework costs: Adjustments to the series tool may be required after initial prototyping\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">Longer setup time: Series tools take the longest to manufacture, so faster alternatives should be considered for urgent samples\u003C/span>\u003C/li>\u003C/ul>",[],{"__component":425,"id":426,"title":427,"link":236,"cta_label":428,"cta_note":429},"page-template.call-to-action",330,"Request Thermoforming Prototypes. With formary.","Receive an offer","Get your free, no-obligation offer for your thermoformed prototype today.",{"__component":431,"id":432,"title":433,"variant":242,"first_accordion_open":434,"accordions":435},"page-template.accordion",430,"Tooling Options for Thermoformed Plastic Parts",false,[436,440,444,448,452],{"id":437,"title":438,"content":439},2553,"Positive or Negative Molds","\u003Cp>The choice of tooling is primarily determined by dimensional specifications and the draw ratio, which are tailored individually for each project based on its specific requirements.\u003C/p>\u003Cp>In general, functional criteria take precedence in the decision-making process. If these are not a limiting factor, then considerations shift towards cost-effectiveness in tool manufacturing and production-related variables such as cycle times.\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">\u003Cstrong>Positive Molds (Male Molds):\u003C/strong> With positive molds, the material is formed over a raised contour rather than being drawn into a cavity. Generally, positive molds are more cost-effective to manufacture, but they come with the drawback of more challenging demolding, particularly when dealing with undercuts, complex geometries, or materials with significant shrinkage.\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">\u003Cstrong>Negative Molds (Female Molds): \u003C/strong>In negative molds, the cavity itself serves as the forming surface. The shaping process is achieved through vacuum, compressed air, or a combination of both, ensuring precise form definition. Negative molds are often preferred for detailed surface textures and higher precision applications.\u003C/span>\u003C/li>\u003C/ul>",{"id":441,"title":442,"content":443},2554,"Single and Multiple Use","\u003Cul>\u003Cli>\u003Cspan style=\"background-color:transparent;\">\u003Cstrong>Single Use:\u003C/strong> A single-use tool is used when the size of the formed product and the maximum forming area of the machine allow only one part per cycle. It is also the preferred choice for small production runs, where investing in a more expensive multi-use tool would not be cost-effective.\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"background-color:transparent;\">\u003Cstrong>Multiple Use: \u003C/strong>If neither part size nor production volume is a limiting factor, a multi-use tool can be utilized. While more complex in design, multi-use tools enable the production of multiple parts per cycle, reducing overall costs and improving efficiency.\u003C/span>\u003C/li>\u003C/ul>",{"id":445,"title":446,"content":447},2555,"Upper Punch Component","\u003Cp>An upper punch significantly enhances stretching ratios in negative molds, allowing for ratios of up to 1:7 instead of the typical 1:1.\u003C/p>\u003Cp>Since the upper punch acts as a positive tool, pressing the material into the negative cavity, it closely resembles the closed mold setup used in injection molding. This technique improves material distribution and enables the forming of deeper, more complex geometries\u003Cspan style=\"background-color:transparent;\">.\u003C/span>\u003C/p>",{"id":449,"title":450,"content":451},2556,"Form-Punch Tool","\u003Cp>A form-punch tool is a specialized tooling system that combines forming and punching into a single process step, eliminating the need for separate forming and trimming operations.\u003C/p>\u003Cp>In thermoforming, form-punch tools are designed for high precision and repeatability, ensuring consistently accurate parts. They are widely used in mass production, where efficiency and uniformity are critical for cost-effective manufacturing.\u003C/p>",{"id":453,"title":454,"content":455},2557,"Customized Mold Surface Design","\u003Cp>\u003Cspan style=\"background-color:transparent;\">The design of the forming area is automatically calculated and determined by formary after evaluating your relevant inquiry criteria. The requirements for the deep-drawn part converted into production-relevant processes are decisive.\u003C/span>\u003C/p>\u003Cp>\u003Cbr> \u003C/p>",{"__component":457,"id":458,"title":459,"variant":242,"cta_button":85,"blogarticles":460,"style":85},"page-template.blog-teaser",96,"More about Prototyping and Thermoforming Tools",[461,974,1137],{"id":462,"documentId":463,"createdAt":464,"updatedAt":465,"publishedAt":466,"locale":10,"title":467,"introduction":468,"content":469,"slug":470,"cover":471,"seo":527,"blog_author":582,"blogcategory":626,"inline_hubspot_form":85,"blocks":964,"localizations":965},440,"mz4e67e1xf14g08lqy7n7mg4","2026-01-13T15:51:48.233Z","2026-01-26T08:35:24.939Z","2026-01-26T08:35:25.257Z","Rapid Prototyping in Thermoforming – Definition, Benefits & Processes","Rapid prototyping is used in product development to quickly create preliminary models. In thermoforming, rapid prototyping offers numerous advantages for producing high-quality prototypes efficiently and cost-effectively.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Rapid Prototyping?\u003C/span>\u003C/h2>\u003Cp>Rapid Prototyping, also known as Fast Prototyping, refers to the process of quickly and efficiently creating physical models or prototypes of a component or assembly based on three-dimensional CAD/construction data. The prototype serves as the first version of the product, which is thoroughly tested and revised if necessary before mass production.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the Purpose of Rapid Prototyping?\u003C/span>\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Speed:\u003C/strong> Rapid Prototyping enables the production of prototypes in the shortest possible time, significantly accelerating the development process.\u003C/li>\u003Cli>\u003Cstrong>Flexibility:\u003C/strong> The process allows for quick modifications and corrections to prototypes, improving the final product.\u003C/li>\u003Cli>\u003Cstrong>Shorter Time-to-Market:\u003C/strong> The production and delivery of prototypes are significantly shortened, allowing products to be launched faster.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Benefits of Rapid Prototyping\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Early detection of design improvements\u003C/li>\u003Cli>Cost efficiency\u003C/li>\u003Cli>High precision through computer-aided design\u003C/li>\u003Cli>Reduced risk of costly errors\u003C/li>\u003Cli>Ability to present physical prototypes and gather feedback\u003C/li>\u003Cli>Cost-effective integration of customer requirements\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Types of Rapid Prototyping Methods Exist in Thermoforming?\u003C/span>\u003C/h2>\u003Cp>There are four primary Rapid Prototyping methods in thermoforming, depending on the purpose of the sample. The following sections provide an overview of these methods.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping with 3D-Printed Molds\u003C/span>\u003C/h3>\u003Cp>Using 3D-printed thermoforming molds is common for testing critical segments of thermoforming processes. However, due to the high temperatures and mechanical stresses involved in thermoforming, only a small number of samples can be produced from a 3D-printed mold.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:13.2%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/3_D_Druck_Werkzeug_e31f8571e4.png\" alt=\"Rapid Prototyping mit 3D-Werkzeugen\">\u003C/figure>\u003Cul>\u003Cli>\u003Cstrong>Maximum number of samples:\u003C/strong> 1-3 pieces\u003C/li>\u003Cli>\u003Cstrong>Production time (best case):\u003C/strong> 3-5 working days\u003C/li>\u003Cli>\u003Cstrong>Cost:\u003C/strong> €€€€€\u003C/li>\u003C/ul>\u003Ch4>Application Areas:\u003C/h4>\u003Cul>\u003Cli>Testing form-fit accuracy of tray cavities\u003C/li>\u003Cli>Rapid production of prototypes within a few days\u003C/li>\u003Cli>Small batch production in standard material\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages vs. Disadvantages of 3D-Printed Molds\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Disadvantages\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Often cost-effective\u003C/td>\u003Ctd>Layer-based printing (e.g., FDM) results in surface imperfections that may affect aesthetics\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Quick fit testing for tray cavities\u003C/td>\u003Ctd>Some materials (e.g., PP) require heated molds for optimal forming\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping with Ureol Sample Molds\u003C/span>\u003C/h3>\u003Cp>Ureol is a block material used in model making. It can replicate either specific segments or the entire final product, offering a prototype that closely resembles thermoformed parts from aluminum molds. However, due to its lower heat and pressure resistance, only a limited number of samples can be produced.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:18.03%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Musterwerkzeug_aus_Ureol_e5f2632c17.png\" alt=\"Rapid Prototyping mit Musterwerkzeugen aus Ureol\">\u003C/figure>\u003Cp>\u003Cstrong>Specifications:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Maximum number of samples:\u003C/strong> 5-10 pieces\u003C/li>\u003Cli>\u003Cstrong>Production time (best case):\u003C/strong> 1-2 weeks\u003C/li>\u003Cli>\u003Cstrong>Cost:\u003C/strong> €€€€€\u003C/li>\u003C/ul>\u003Cp>\u003Cstrong>Application Areas:\u003C/strong>\u003C/p>\u003Cp>The result is a pattern optimized for 3D printing that takes only slightly longer and costs only slightly more.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages vs. Disadvantages of Ureol Sample Molds\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages of rapid prototyping with sample tools made from Ureol\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Disadvantages of rapid prototyping with sample tools made of ureol\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>The samples produced are almost ready for series production, but show slight differences in quality compared to aluminum tools.\u003C/td>\u003Ctd>Additional costs: The Ureol tool only serves as an intermediate step prior to the production of the series tool.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>The price is only about 20-30% of the price of a production tool, depending on the contour and complexity of the milling work.\u003C/td>\u003Ctd>The series tool is only manufactured after approval, which extends the project schedule by another 2-3 weeks.\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid prototyping with partial segment series tools\u003C/span>\u003C/h3>\u003Cp>A partial segment aluminum tool optimally reproduces your deep-drawn part and enables cost savings compared to series production. This can be achieved, for example, by using a simple tool instead of a multi-cavity tool.\u003C/p>\u003Cp>\u003Cstrong>Please note:\u003C/strong> The sample tool is an intermediate step to the aluminum series tool, and the additional time required for its production must be taken into account in the project planning.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:10.81%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Teilsegment_Serienwerkzeug_ab27e3a164.png\" alt=\"Rapid Prototyping mit Teilsegment-Serienwerkzeug\">\u003C/figure>\u003Cul>\u003Cli>Maximum number of samples: unlimited\u003C/li>\u003Cli>Production period (best case): 2-3 weeks\u003C/li>\u003Cli>Price: €€€€€\u003C/li>\u003C/ul>\u003Ch4>Areas of application\u003C/h4>\u003Cp>Testing a sub-segment using series production tools provides the most realistic result for series production. It should be possible to abstract the lessons learned from the sub-segment to the entire tray.\u003C/p>\u003Ch4>Overview of the advantages and disadvantages of rapid prototyping with sub-segment series production tools\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Disadvantages\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Closely replicates serial production quality\u003C/td>\u003Ctd>Additional production step delays final mold approval by 2-3 weeks\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>More affordable than a full-scale production mold\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Can be adjusted for final production after approval\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid prototyping with series production tools\u003C/span>\u003C/h3>\u003Cp>The aluminum series production tool is also used to manufacture release samples. The deep-drawn parts produced using this tool are manufactured under optimal conditions in terms of elongation, heat, and cooling behavior.\u003C/p>\u003Cp>The production rate per unit of time is a decisive factor in terms of price, particularly for medium to high production volumes, which is why large multi-purpose tools are often used.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:29.33%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Serienwerkzeug_edcc0ae7bc.png\" alt=\"Rapid Prototyping mit Serienwerkzeug\">\u003C/figure>\u003Cul>\u003Cli>Maximum number of samples: unlimited\u003C/li>\u003Cli>Production time (best case): 2-6 weeks (depending on size, design, and number of functions, as well as any special components required; up to 10 weeks possible)\u003C/li>\u003Cli>Price: €€€€€\u003C/li>\u003C/ul>\u003Ch4>Area of application\u003C/h4>\u003Cp>Series tools are naturally the prototyping method that takes the longest to produce. They are therefore primarily used for the approval of the series product before series production starts – not necessarily for the empirical determination of test-relevant points, such as sample variants 1-3.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Overview of the advantages and disadvantages of rapid prototyping with series production tools\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Advantages of rapid prototyping with production tools\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Disadvantages of rapid prototyping with production tools\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>High-quality production of deep-drawn parts \u003C/td>\u003Ctd>Possible effort for reworking on the production tool\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>No additional tool costs before the start of series production\u003C/td>\u003Ctd>Production tools have the longest manufacturing time, so it is advisable to opt for a simplified version for urgently needed samples\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Samples are usually included in the price of the series tool\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Time savings, as no additional approval steps are required\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid prototyping applications\u003C/span>\u003C/h2>\u003Cp>Rapid prototyping in deep drawing is used in a wide range of industries, including:\u003C/p>\u003Cul>\u003Cli>Automotive: Prototypes of vehicle parts such as dashboards, door panels, and bumpers can be produced quickly and cost-effectively.\u003C/li>\u003Cli>Medical and pharmaceutical: The production of prototypes for medical devices and housing enables manufacturers to develop and test new products quickly.\u003C/li>\u003Cli>\u003Cstrong>Packaging industry\u003C/strong>: Prototypes of packaging and plastic containers can be created to test their functionality and aesthetics before they go into mass production.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid prototyping in deep drawing – a summary\u003C/span>\u003C/h2>\u003Cp>Rapid prototyping in deep drawing offers a wide range of options for creating high-quality prototypes of parts and components \u003Cstrong>quickly and cost-effectively\u003C/strong>. By combining speed and flexibility, the fast prototyping process simplifies product development and enables formary to bring innovative products to market faster.\u003C/p>\u003Cp>Get in touch with us now!\u003C/p>","rapid-prototyping-in-thermoforming",{"id":472,"documentId":473,"name":474,"alternativeText":475,"caption":16,"width":367,"height":361,"formats":476,"hash":522,"ext":150,"mime":153,"size":523,"url":524,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":525,"updatedAt":525,"publishedAt":526},2090,"kit4t8jkrcu5r3upambv73ah","Rapid Prototyping Blog Banner Eng .png","Rapid Prototyping in Thermoforming",{"lg":477,"md":482,"sm":488,"xl":493,"2xl":499,"avatar":505,"default":511,"thumbnail":516},{"ext":150,"url":478,"hash":479,"mime":153,"name":480,"path":85,"size":481,"width":156,"height":344},"https://fsn1.your-objectstorage.com/formary-de-production-cms/lg_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","lg_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","lg_Rapid Prototyping Blog Banner Eng .png",262.2,{"ext":150,"url":483,"hash":484,"mime":153,"name":485,"path":85,"size":486,"width":163,"height":487},"https://fsn1.your-objectstorage.com/formary-de-production-cms/md_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","md_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","md_Rapid Prototyping Blog Banner Eng .png",135.31,432,{"ext":150,"url":489,"hash":490,"mime":153,"name":491,"path":85,"size":492,"width":170,"height":379},"https://fsn1.your-objectstorage.com/formary-de-production-cms/sm_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","sm_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","sm_Rapid Prototyping Blog Banner Eng .png",92.24,{"ext":150,"url":494,"hash":495,"mime":153,"name":496,"path":85,"size":497,"width":176,"height":498},"https://fsn1.your-objectstorage.com/formary-de-production-cms/xl_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","xl_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","xl_Rapid Prototyping Blog Banner Eng .png",314.48,720,{"ext":150,"url":500,"hash":501,"mime":153,"name":502,"path":85,"size":503,"width":183,"height":504},"https://fsn1.your-objectstorage.com/formary-de-production-cms/2xl_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","2xl_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","2xl_Rapid Prototyping Blog Banner Eng .png",322.84,810,{"ext":150,"url":506,"hash":507,"mime":153,"name":508,"path":85,"size":509,"width":190,"height":510},"https://fsn1.your-objectstorage.com/formary-de-production-cms/avatar_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","avatar_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","avatar_Rapid Prototyping Blog Banner Eng .png",11.48,70,{"ext":150,"url":512,"hash":513,"mime":153,"name":514,"path":85,"size":515,"width":197,"height":34},"https://fsn1.your-objectstorage.com/formary-de-production-cms/default_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","default_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","default_Rapid Prototyping Blog Banner Eng .png",59.29,{"ext":150,"url":517,"hash":518,"mime":153,"name":519,"path":85,"size":520,"width":204,"height":521},"https://fsn1.your-objectstorage.com/formary-de-production-cms/thumbnail_Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","thumbnail_Rapid_Prototyping_Blog_Banner_Eng_911b90221b","thumbnail_Rapid Prototyping Blog Banner Eng .png",27.73,138,"Rapid_Prototyping_Blog_Banner_Eng_911b90221b",86.93,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Rapid_Prototyping_Blog_Banner_Eng_911b90221b.png","2025-06-02T17:15:39.000Z","2026-01-08T22:06:18.091Z",{"id":528,"open_graph_title":529,"open_graph_description":530,"title":529,"description":530,"open_graph_image":531},2500,"Rapid prototyping in deep drawing","Rapid prototyping in deep drawing: ✓ Rapid prototyping definition ✓ Rapid prototyping advantages ✓ Rapid prototyping process ➡️ Read now!",{"id":532,"documentId":533,"name":534,"alternativeText":535,"caption":16,"width":367,"height":361,"formats":536,"hash":577,"ext":150,"mime":153,"size":578,"url":579,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":580,"updatedAt":580,"publishedAt":581},2091,"tu5nszb28y8l0ofb00qh5e9x","Rapid Prototyping im Tiefziehen - 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Definition, Vorteile & Verfahren SEO Banner",27.75,"Rapid_Prototyping_im_Tiefziehen_Definition_Vorteile_and_Verfahren_SEO_Banner_5f4787ed93",136.63,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Rapid_Prototyping_im_Tiefziehen_Definition_Vorteile_and_Verfahren_SEO_Banner_5f4787ed93.png","2025-06-02T17:19:47.000Z","2026-01-08T22:06:18.204Z",{"id":583,"documentId":584,"createdAt":585,"updatedAt":585,"publishedAt":586,"locale":10,"role":587,"name":588,"email":589,"phone":590,"meeting_url":591,"image":592,"localizations":620},52,"umk62m0sgi9fe20ee90o9b9f","2026-01-16T11:13:10.227Z","2026-01-16T11:13:10.247Z","PR Managerin","Sarah Guaglianone","sarah.guaglianone@formary.de","015202087894","https://meetings.hubspot.com/sarah-guaglianone",{"id":593,"documentId":594,"name":595,"alternativeText":596,"caption":16,"width":170,"height":597,"formats":598,"hash":615,"ext":150,"mime":153,"size":616,"url":617,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":618,"updatedAt":618,"publishedAt":619},1874,"s0go9m7qi1x2yvzea71n71bn","Sarah Guaglianone - Marketing & PR.png","Sarah Guaglianone - Marketing & PR",638,{"avatar":599,"default":604,"thumbnail":610},{"ext":150,"url":600,"hash":601,"mime":153,"name":602,"path":85,"size":603,"width":190,"height":190},"https://fsn1.your-objectstorage.com/formary-de-production-cms/avatar_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","avatar_Sarah_Guaglianone_Marketing_and_PR_883577361c","avatar_Sarah Guaglianone - Marketing & PR.png",26.2,{"ext":150,"url":605,"hash":606,"mime":153,"name":607,"path":85,"size":608,"width":197,"height":609},"https://fsn1.your-objectstorage.com/formary-de-production-cms/default_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","default_Sarah_Guaglianone_Marketing_and_PR_883577361c","default_Sarah Guaglianone - Marketing & PR.png",340.33,479,{"ext":150,"url":611,"hash":612,"mime":153,"name":613,"path":85,"size":614,"width":385,"height":385},"https://fsn1.your-objectstorage.com/formary-de-production-cms/thumbnail_Sarah_Guaglianone_Marketing_and_PR_883577361c.png","thumbnail_Sarah_Guaglianone_Marketing_and_PR_883577361c","thumbnail_Sarah Guaglianone - Marketing & PR.png",40.8,"Sarah_Guaglianone_Marketing_and_PR_883577361c",160.34,"https://fsn1.your-objectstorage.com/formary-de-production-cms/Sarah_Guaglianone_Marketing_and_PR_883577361c.png","2025-03-10T12:07:01.000Z","2026-01-08T22:05:48.776Z",[621],{"id":622,"documentId":584,"createdAt":623,"updatedAt":623,"publishedAt":624,"locale":128,"role":625,"name":588,"email":589,"phone":590,"meeting_url":591},22,"2026-01-09T11:19:33.660Z","2026-01-13T11:12:23.682Z","Marketing und PR Managerin",{"id":627,"documentId":628,"createdAt":629,"updatedAt":630,"publishedAt":631,"locale":10,"title":632,"slug":633,"description":634,"blogarticles":635,"seo":953,"localizations":956},47,"nm4hkxw9ydvlepb5n0fbq8ls","2026-01-13T16:44:17.483Z","2026-01-26T08:25:05.206Z","2026-01-26T08:25:05.256Z","Thermoformed Parts in Practice","thermoformed-parts-in-practice","All insights into the practice of thermoforming. Useful tips on what to consider. Here you will find entries on all aspects of thermoforming.",[636,646,656,666,676,686,696,706,716,726,736,746,756,765,766,776,786,796,806,816,826,836,846,856,866,876,886,896,906,915,925,935,944],{"id":637,"documentId":638,"createdAt":639,"updatedAt":640,"publishedAt":641,"locale":10,"title":642,"introduction":643,"content":644,"slug":645},449,"r3y5ruu65xv9w55humtuk1ws","2026-01-13T15:51:49.911Z","2026-01-26T08:40:28.415Z","2026-01-26T08:40:28.455Z","Automation of Production - How Trays Support Automation in Industry 4.0","Trays for automation are workpiece carriers that pass through an automated industrial system or production line, fulfilling various functions along the way.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Automation?\u003C/span>\u003C/h2>\u003Cp>In Industry 4.0, automation of production is crucial. It is based on the networking of machines and systems to create a smart factory where processes run autonomously and in real time. Production automation enables the use of modern technologies that make production processes not only more efficient and flexible but also better aligned with individual needs.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Foerderband_mit_Industrierobotern_77c7afd4f6.png\" alt=\"Industrieroboter zur Automatisierung der Produktion\">\u003C/figure>\u003Cp>Technologies like industrial robots, computer-controlled machines (CNC), and sensors improve operational safety and ensure consistently high production quality. In industrial manufacturing, many processes, from production to logistics, can be automated. This autonomy increases efficiency, reduces errors, and is a key element of automation technology. In the following sections, you’ll learn how trays enable production automation.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Processes Can Be Automated in Industrial Production?\u003C/span>\u003C/h2>\u003Cp>Modern manufacturing presents many challenges in automating production, especially when optimizing key processes. Below are some of the central processes that are commonly automated:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Inbound Logistics\u003C/span>\u003C/h3>\u003Cp>The supplier delivers components just-in-time. These parts are added to production and packaged in sensible quantities on pallets.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Production\u003C/span>\u003C/h3>\u003Cp>Once on the production line, parts are automatically fed into production in a plastic tray (also called a workpiece carrier), designed for automation. This workpiece carrier is constructed to ensure the parts pass through all processing stages, and it can accommodate different versions of the part.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Outbound Logistics\u003C/span>\u003C/h3>\u003Cp>Once the part has passed through the production line, the automation tray provides the perfect solution. The tray, designed for production automation, serves for transporting precise packaging units and is used as a reusable transit package to your end customers.\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Werkstuecktraeger_7ae6aaee4c.png\" alt=\"Trays zur Produktionsautomatisierung\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Fully or Semi-Automated Production – How Trays Are Used for Automation\u003C/span>\u003C/h2>\u003Cp>Within the system, the part and tray autonomously pass through various production stages, including measuring/testing, loading and assembly, and packaging and removal from the tray.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Production Automation in the Manufacturing Line\u003C/span>\u003C/h3>\u003Cp>The automation tray is adapted to the dimensions of the transport belts in the system. Usually, the dimensions also match standard industrial containers. All common \"standardizations\" are stored in the formary database. The tray is autonomously handled by a palletizer, which loads and removes it from the system.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Optimal Tray Design for Automation in Production\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50.37%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Formnester_35b63810f1.png\" alt=\"Formnester bei Automatisierungstrays\">\u003C/figure>\u003Cp>Before development, consideration must be given to how many and what type of parts the tray needs to accommodate. The tray for production automation and the part cavities must be multifunctional to handle every step of the automated production process.\u003C/p>\u003Cp>Various external shapes, depths, and edges support automated processes and provide space for each part version. The cavity shape in the tray is also determined by the technology or robotics that removes and loads the parts.\u003C/p>\u003Cp>The desired packing density (parts per tray) also plays a role in the design, as well as how their positioning is defined. Many production systems require parallel and non-offset positioning of all parts to allow industrial robots to handle them efficiently in the automation process.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">How Trays Further Support Process Automation\u003C/span>\u003C/h3>\u003Cp>Industrial robots are key in production automation. Primarily, they are responsible for loading and unloading parts in and out of the tray. The edge contour and wall construction depend on the symmetry of the parts and can be supported both visually and mechanically. To position the parts, elements like Poka-Yoke pins can be added to the tray.\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/Poka_Yoke_Ecken_zur_Automatisierung_der_Produktion_a734699f7a.png\" alt=\"Poka-Yoke Ecken zur Automatisierung der Produktion\">\u003Cfigcaption>Poka-Yoke Edges\u003C/figcaption>\u003C/figure>\u003Cp>The design of the automation tray is based on the robot used: Where should the robot arm grip the part to ensure a secure hold, considering the size, weight, and geometry of the part? The nesting contour is adapted to the optimal stroke of the gripper fingers. The gripper jaw coating should be adapted to the pick-and-place task.\u003C/p>\u003Cp>Robot arms have different capabilities. Simple grippers follow the same path, while more complex systems work with integrated image processing and path measurement systems that can approach contours and parts more easily. Depending on the system, the tolerance range of the tray interacts with the system.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does the system capture tray data for production automation?\u003C/span>\u003C/h2>\u003Cp>Automation trays can be encoded so that sensors can capture them and collect essential data. Options include binary detection systems in the tray frame and applying markings such as RFID chips, transponders, or fixed engravings that can be recognized and tracked. More information can be found under “Plastic Automation Trays.”\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.47%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/automatisierung_transponder_01_875c07872a.png\" alt=\"Integrierter Transponder am Tray zur Automatisierung der Produktion\">\u003Cfigcaption>Integrated Transponder on the automation tray\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Automation of Industry 4.0 Manufacturing through Trays – A Conclusion\u003C/span>\u003C/h2>\u003Cp>The integration of trays into automated manufacturing processes offers an efficient solution to the challenges faced by modern industries. The adaptability to different manufacturing systems, as well as support for robotics, helps increase efficiency and precision. Ultimately, trays for production automation support and optimize Industry 4.0 in many areas.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Request Now – Quickly Get the Perfect Tray for Automating Your Production\u003C/span>\u003C/h3>\u003Cp>Let us design your tray for automating your processes. Simply click \"Automation\" in the formary configurator. formary will ask for all the relevant information.\u003C/p>\u003Cp>If you already have 3D data, you can also visualize it in our 3D Tray Generator. Simply book a \u003Cspan style=\"color:#005250;\">\u003Cstrong>live demo\u003C/strong>\u003C/span> and we will show you how it works and whether your data is suitable for deep drawing.\u003C/p>\u003Cp>Still have something to say or more questions? Contact us via live chat or call us at: +497191 9525170.\u003C/p>","automation-of-production-with-trays",{"id":647,"documentId":648,"createdAt":649,"updatedAt":650,"publishedAt":651,"locale":10,"title":652,"introduction":653,"content":654,"slug":655},439,"my3ss0y0qmen3dlue8sg3mzu","2026-01-13T15:51:48.023Z","2026-01-26T08:34:53.736Z","2026-01-26T08:34:55.062Z","Component Safety for Your Small Parts: How Thermoformed Plastic Inserts Ensure Secure Transport","Delicate components require protection against damage to prevent costs and downtime. Thermoformed plastic inserts provide an efficient solution for safe transport and storage. In this article, you will learn how thermoformed inserts optimize component safety.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Component Safety?\u003C/span>\u003C/h2>\u003Cp>\u003Cstrong>Definition:\u003C/strong> Component safety includes all measures designed to protect sensitive or valuable components from damage. This involves specialized packaging solutions and transport aids that ensure secure handling. Protection can include the following aspects:\u003C/p>\u003Col>\u003Cli>\u003Cstrong>Mechanical Protection\u003C/strong> – Prevents scratches, impacts, dents, or other damage from external forces.\u003C/li>\u003Cli>\u003Cstrong>Chemical Protection \u003C/strong>– Shields components from corrosion, moisture, or harmful chemicals.\u003C/li>\u003Cli>\u003Cstrong>ESD Protection\u003C/strong> – Prevents damage from electrostatic discharge (ESD), which is especially crucial in the electronics industry.\u003C/li>\u003C/ol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Bauteile_fuer_Tiefzieheinlagen_e81d4dafad.png\" alt=\"Bauteile für Tiefzieheinlagen\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Thermoformed Plastic Inserts Protect Your Components\u003C/span>\u003C/h2>\u003Cp>Thermoformed inserts, also known as inlays, are produced using the \u003Cstrong>plastic thermoforming process\u003C/strong>. Through \u003Cstrong>sheet or roll production\u003C/strong>, plastic films are heated and shaped into a mold. The result includes not only inserts but also \u003Cstrong>plastic trays, covers, and containers\u003C/strong>.\u003C/p>\u003Cp>These inserts securely hold products or bulk materials in a \u003Cstrong>custom-fit blister\u003C/strong> within a container or box. Their \u003Cstrong>precise shape prevents movement\u003C/strong>, ensuring that sensitive components remain in place. This is especially crucial for \u003Cstrong>delicate parts or products\u003C/strong> that require a specific orientation during assembly. By securing components, \u003Cstrong>thermoformed inserts prevent transport damage and ensure component safety\u003C/strong>.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Standard_Tiefzieheinlagen_aus_Kunststoff_b6c50d999e.png\" alt=\"Standard Tiefzieheinlagen aus Kunststoff\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Component Safety for ESD-Sensitive Parts\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:25.11%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/ESD_Tiezfieheinlage_zur_Bauteilsicherheit_von_elektronischen_Teilen_0dab016189.png\" alt=\"Tiefzieheinlage\">\u003C/figure>\u003Cp>In the \u003Cstrong>electronics industry\u003C/strong>, protecting delicate components from \u003Cstrong>electrostatic discharge (ESD)\u003C/strong> is crucial. This electrical discharge can \u003Cstrong>irreparably damage\u003C/strong> electronic parts, leading to \u003Cstrong>production failures or quality defects\u003C/strong>.\u003C/p>\u003Cp>To prevent this, \u003Cstrong>ESD inserts and trays\u003C/strong> are specially designed to securely store and transport electronic components, ensuring \u003Cstrong>safe handling throughout the logistics chain\u003C/strong>.\u003C/p>\u003Ch3>Industries That Rely on Thermoformed Inserts for Component Safety\u003C/h3>\u003Cp>Thermoformed plastic inserts serve as \u003Cstrong>protective transport solutions\u003C/strong> across various industries. Here are some examples:\u003C/p>\u003Cp> \u003C/p>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cstrong>Industry\u003C/strong>\u003C/p>\u003C/th>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cstrong>Use Case for Thermoformed Inserts\u003C/strong>\u003C/p>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Automotive\u003C/strong>\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Protection for body parts, electronic modules, and engine components\u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Electronics\u003C/strong>\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Safe transport of sensitive circuit boards and semiconductor components\u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Medical Technology\u003C/strong>\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Secure storage of precision instruments and implants\u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">\u003Cstrong>Logistics & Packaging\u003C/strong>\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Interlayers for stackable containers and pallets\u003C/p>\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why Are Thermoformed Plastic Inserts Ideal for Component Safety?\u003C/span>\u003C/h2>\u003Cp>Thermoformed \u003Cstrong>plastic inserts\u003C/strong> are widely used as \u003Cstrong>durable inlays\u003C/strong> in \u003Cstrong>small load carriers (KLTs) and Euro containers\u003C/strong>, which often endure \u003Cstrong>intensive use\u003C/strong>. For \u003Cstrong>heavy-duty applications\u003C/strong>, such as protecting tools, the material must be particularly \u003Cstrong>robust\u003C/strong>.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffflakes_die_sich_in_den_Haenden_befinden_66b91b7e44.png\" alt=\"Kunststoff Granulat\">\u003C/figure>\u003Cp>Plastic is the preferred material for thermoformed inserts due to its versatility and durability. Key benefits include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Lightweight & Long-Lasting\u003C/strong> – Reduces overall weight while withstanding heavy use.\u003C/li>\u003Cli>\u003Cstrong>Flexible & Malleable\u003C/strong> – Easily heated and shaped into \u003Cstrong>precise, custom designs\u003C/strong>.\u003C/li>\u003Cli>\u003Cstrong>Shock-Absorbing\u003C/strong> – Thermoplastics provide \u003Cstrong>impact resistance\u003C/strong>, protecting fragile components.\u003C/li>\u003Cli>\u003Cstrong>Chemical & Corrosion Resistant\u003C/strong> – Most plastics do not react with water, acids, or bases, making them \u003Cstrong>ideal for humid or chemically demanding environments\u003C/strong>.\u003C/li>\u003C/ul>\u003Cp>Commonly Used Plastics in Thermoforming:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>PS (Polystyrene)\u003C/strong> – The \u003Cstrong>standard reference material\u003C/strong> for thermoforming, known for its \u003Cstrong>hardness and chemical resistance\u003C/strong>, making it \u003Cstrong>ideal for transport applications\u003C/strong>.\u003C/li>\u003Cli>\u003Cstrong>ABS (Acrylonitrile Butadiene Styrene)\u003C/strong> – Offers \u003Cstrong>high impact resistance\u003C/strong> and is widely used in \u003Cstrong>automotive and industrial applications\u003C/strong>.\u003C/li>\u003Cli>\u003Cstrong>PP (Polypropylene)\u003C/strong> – Known for its \u003Cstrong>flexibility and heat resistance\u003C/strong>, often used in \u003Cstrong>food and medical industries\u003C/strong>.\u003C/li>\u003C/ul>\u003Cp>When designing the insert, it is important to consider the requirements that the plastic used must meet in order to ensure smooth transport protection for the components.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Component Safety for Your Parts – With formary Standard Thermoformed Inserts\u003C/span>\u003C/h3>\u003Cp>Effective \u003Cstrong>component protection\u003C/strong> is essential to ensure products \u003Cstrong>arrive safely and undamaged\u003C/strong>. Our \u003Cstrong>high-quality thermoformed inserts\u003C/strong> provide \u003Cstrong>secure storage and transport\u003C/strong> for your parts.\u003C/p>\u003Cp>\u003Cstrong>Do you have questions or need personalized advice?\u003C/strong> Contact us today – we’ll help you find the \u003Cstrong>perfect protective solution\u003C/strong> for your components!\u003C/p>","component-safety-for-small-parts",{"id":657,"documentId":658,"createdAt":659,"updatedAt":660,"publishedAt":661,"locale":10,"title":662,"introduction":663,"content":664,"slug":665},427,"hrt0o90vioejy5nuiggttsi8","2026-01-13T15:51:45.749Z","2026-01-26T08:29:16.355Z","2026-01-26T08:29:16.642Z","ESD Trays Made of Plastic – Applications and Benefits","Electrostatic discharge (ESD) can irreparably damage sensitive components and incur high costs. To ensure that electronic components are optimally protected during manufacturing, storage, and delivery, ESD trays made of plastic are used.","\u003Ch2>What is an ESD Tray?\u003C/h2>\u003Cp>An ESD tray is a plastic workpiece carrier designed to protect electronic components from damage caused by electrostatic discharge (ESD). ESD, which stands for \"Electrostatic Discharge,\" can cause significant harm to sensitive electronic parts. ESD trays are specially designed to prevent electrostatic discharge, ensuring a safe environment for the components.\u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:19.55%;\">\u003Ca href=\"https://www.formary.de/branchen/elektronik-halbleitertechnologie\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/ESD_Tray_9be91e6c40.jpg\" alt=\"ESD Trays in der Elektronikbranche\">\u003C/a>\u003Cfigcaption>ESD Trays in the Electronics Industry\u003C/figcaption>\u003C/figure>\u003Cp>Protection is ensured through the material composition of the tray, which consists of plastics enriched with conductive or antistatic additives. This combination helps to dissipate static charges before they can reach sensitive components.\u003C/p>\u003Ch3>How Does an ESD Tray Work?\u003C/h3>\u003Cp>The function of an ESD tray relies on three key material properties:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Electrical Conductivity\u003C/strong>: The addition of additives like carbon black or graphite makes the plastic electrically conductive, allowing static charges to be efficiently dissipated.\u003C/li>\u003Cli>\u003Cstrong>Antistatic Effect\u003C/strong>: Antistatic additives prevent static charges from forming on the surface of the ESD tray.\u003C/li>\u003Cli>\u003Cstrong>Surface Protection\u003C/strong>: The smooth, specially treated surface of the ESD workpiece carriers not only protects against scratches but also prevents dust or particles from accumulating, which could otherwise lead to static buildup.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"background-color:hsl(0,0%,100%);color:rgb(41,41,41);\">Materials and Manufacturing Processes for ESD Workpiece Carriers\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:#0c0c0c;\">The base material of an ESD tray is a thermoplastic plastic, modified to be electrically conductive or antistatic. Commonly used thermoplastics include ABS (Acrylonitrile Butadiene Styrene Copolymer) and PS (Polystyrene). These plastics are combined with conductive additives like carbon black or graphite and antistatic substances to achieve the desired properties.\u003C/span>\u003C/p>\u003Ch2>How are ESD Trays Made?\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Material Preparation\u003C/strong>: During plastic extrusion, plastic granules are carefully mixed with additives and antistatic agents to ensure the desired material properties.\u003C/li>\u003Cli>\u003Cstrong>Shaping\u003C/strong>: The plastic is heated and molded into its final form through thermoforming.\u003C/li>\u003Cli>\u003Cstrong>Quality Control\u003C/strong>: Finally, the ESD packaging is tested for electrical conductivity, antistatic properties, and mechanical stability.\u003C/li>\u003C/ul>\u003Ch2>Applications of ESD Trays\u003C/h2>\u003Cp>ESD trays are used across various industries to ensure safe storage and reliable transport of sensitive electronics:\u003C/p>\u003Ch3>Typical Fields of Application for ESD Trays\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Electronics Manufacturing\u003C/strong>: In the electronics industry, ESD trays are used to transport and safely store components such as semiconductors, circuit boards, or chips between different stages of production.\u003C/li>\u003Cli>\u003Cstrong>Automotive\u003C/strong>: Modern vehicles contain sensitive control units and sensors that need protection during production and delivery.\u003C/li>\u003Cli>\u003Cstrong>Medical & Pharma\u003C/strong>: Diagnostic devices and their components also require high protection from electrostatic discharge.\u003C/li>\u003C/ul>\u003Ch3>\u003Cstrong>Typical Components that Require ESD Trays\u003C/strong>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Electronics Manufacturing\u003C/strong>: Semiconductors, circuit boards\u003C/li>\u003Cli>\u003Cstrong>Automotive Industry\u003C/strong>: Control units, sensors\u003C/li>\u003Cli>\u003Cstrong>Medical & Lab Technology\u003C/strong>: Diagnostic chips, modules\u003C/li>\u003C/ul>\u003Ch3>\u003Cstrong>Overview of ESD Workpiece Carrier Applications\u003C/strong>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">Areas of application for ESD trays\u003C/p>\u003C/th>\u003Cth>\u003Cp style=\"text-align:center;\">Typical components that require ESD trays\u003C/p>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Electronics manufacturing \u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Semiconductors, printed circuit boards \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Automotive\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Control units, sensors \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Medical and laboratory technology\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Diagnostic chips, modules \u003C/p>\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>Advantages of Plastic ESD Trays\u003C/h2>\u003Cp>Plastic ESD workpiece carriers offer several additional benefits for handling sensitive components. Their function is similar to that of conventional plastic trays, with added advantages:\u003C/p>\u003Ch3>Durability\u003C/h3>\u003Cp>Plastic ESD trays are made from high-quality materials that provide excellent strength and durability. Compared to traditional cardboard or foam trays, plastic ESD trays are more resistant to impacts, vibrations, and moisture.\u003C/p>\u003Ch3>Customization for Your Needs\u003C/h3>\u003Cp>Electronic components come in various sizes and shapes. ESD trays are highly customizable and can be designed to meet specific customer requirements. This allows components to be safely and efficiently positioned and transported in the ESD packaging, making it an ideal packaging solution.\u003C/p>\u003Ch3>Optimierte Lagerung und Transport\u003C/h3>\u003Cp>ESD trays are ergonomically designed and easy to handle. They can be equipped with integrated handles for easy gripping and transport.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:13.88%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Gestapelte_ESD_Trays_f91070dd07.png\" alt=\"Gestapelte ESD Trays\">\u003C/figure>\u003Cp>Additionally, plastic ESD trays are stackable, ensuring optimal storage and shipping. Transparent ESD trays also allow easy identification and organization of electronic components.\u003C/p>\u003Ch3>Reusability\u003C/h3>\u003Cp>Compared to single-use packaging, plastic ESD trays offer a more sustainable option. ESD workpiece carriers can be designed for multiple uses, reducing waste and the need for single-use materials like cardboard or foam. At the end of their lifecycle, plastic trays can also be recycled to further improve resource efficiency.\u003C/p>\u003Ch3>ESD Trays for Your Application\u003C/h3>\u003Cp>Are you looking for a tailored solution to protect your valuable electronic components? There are more options than just ESD trays for protecting your electronics, such as plastic enclosures for electronics, ESD transport packaging, and more.\u003C/p>\u003Cp>Use our configurator to design your personalized thermoformed part in ESD execution.\u003C/p>\u003Cp> \u003C/p>","esd-trays",{"id":667,"documentId":668,"createdAt":669,"updatedAt":670,"publishedAt":671,"locale":10,"title":672,"introduction":673,"content":674,"slug":675},452,"t8cdf4kf19se6cjzzzao0d9i","2026-01-13T15:51:50.468Z","2026-01-26T08:41:41.310Z","2026-01-26T08:41:41.847Z","Determining the Mold Nests of Your Workpiece Carrier","Mold nests or cavities can be diverse: rectangular, round, custom-shaped, tracks, ribs, or domes. So how is it decided which mold nest is the right one? More on this in the article.","\u003Cp>The shape of the cavity that holds the component is often the critical point for its functionality. Whether for inlays, blisters, transport trays, or workpiece carriers—how well the cavity fits the product determines the efficiency and safety during handling, transport, and storage.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are mold nests? What is a cavity?\u003C/span>\u003C/h2>\u003Cp>Mold nests are cavities that hold the component. The term \"cavity\" comes from the Latin \"cavum,\" meaning hollow. In simple terms, mold nests are recesses in the workpiece carrier designed for secure transport of the component and to simplify loading and unloading of the trays.\u003C/p>\u003Cp>The shape of the cavity that holds the component is often the key to functionality. Whether for inlays, blisters, transport trays, or workpiece carriers, the better the cavity fits the product, the more efficient and safe the handling, transport, and storage will be.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Typical requirements for mold nests and cavities\u003C/span>\u003C/h2>\u003Cp>In both intralogistics and extralogistics, the primary goal is cost savings.\u003C/p>\u003Cp>One way this is achieved is by saving volume and using space more efficiently. For transporting components on trays, a high packing density is essential. This means achieving a minimal transport volume by placing as many components as possible per tray. Therefore, the mold nests and cavities must be designed to maximize the packing density.\u003C/p>\u003Cp>At the same time, costs can be saved if as many different components as possible can be transported in a universal tray. This means fewer tray variants and lower investment and handling costs. In this case, the mold nests are designed as universal nests.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What affects the maximum packing density of mold nests and cavities?\u003C/span>\u003C/h2>\u003Cp>The maximum packing density is usually determined by your application specifications, thermoforming limitations, and, if the trays are used on automated production lines, the capabilities of the system/robot. Based on these specifications, the goal is to fill the available space as efficiently as possible with mold nests.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1.) Users often specify a minimum distance for the cavities:\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Distance between mold nests\u003C/li>\u003Cli>Distance from mold nest to the outer edge of the tray These specifications have ergonomic reasons for non-automated processes. Manual loading and handling of the trays should be simple. For example, components should be easily removed from the cavity, or trays should be quickly placed into a secondary container.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">2.) What do the mold nests require?\u003C/span>\u003C/h3>\u003Cul>\u003Cli>The mold nests need a draft angle of at least 2-5°. This draft angle is needed for thermoforming so the tray can be lifted off the deep-drawing tool.\u003C/li>\u003C/ul>\u003Cp>This impacts the arrangement of the cavities on the tray, as well as the distances between the mold nests. CAD programs have a draft angle analysis feature to optimize the packing density of tightly packed trays.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3.) What requirements does the automated system have for the cavities?\u003C/span>\u003C/h3>\u003Col>\u003Cli>Edge geometry of the nest opening\u003C/li>\u003Cli>Gripper type and gripper technique\u003C/li>\u003Cli>Nest depth In automation projects, there are additional requirements for nest production. The maximum packing density is always the result of the equation of the above factors.\u003C/li>\u003C/ol>\u003Ch3>\u003Cspan style=\"color:#005250;\">How are universally usable mold nests designed?\u003C/span>\u003C/h3>\u003Cp>When investing in the development of a transport tray, the design of a universal tray is often required. A universal tray can transport different component variants or families of components. This saves on tool costs, which would be incurred for each tray variant.\u003C/p>\u003Cp>This means the mold nests must be adapted to various components.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What should be considered when developing universal mold nests?\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Position:\u003C/strong> If placing the components in a horizontal position is not possible due to different dimensions, much space can be wasted.\u003C/li>\u003Cli>\u003Cstrong>Unequal outer sizes and/or contours:\u003C/strong> The contours must roughly match, or else it will be difficult to design.\u003C/li>\u003Cli>\u003Cstrong>Sensitive areas:\u003C/strong> If certain parts of the component need to be free, it is often hard to find a middle ground.\u003C/li>\u003Cli>\u003Cstrong>Placing components at different levels:\u003C/strong> Steps and tight contours in some materials, like PC, are difficult to form.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">How are mold nests 100% adapted to the component?\u003C/span>\u003C/h2>\u003Cp>A cavity is always aligned with the original component. This is done using the CAD data of the components, a component prototype, or an existing tray.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">How are nest data created?\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>CAD data:\u003C/strong> The best way for the customer and formary is to create data from the CAD files of the component. This allows for optimal measurement of all sides of the component. No time-consuming adjustments to the data are necessary. Additionally, finer details, such as the gap between the component and the nest's inner wall, can be adjusted in advance. Before data creation, a confidentiality agreement (NDA) is signed.\u003C/li>\u003Cli>\u003Cstrong>Component prototype:\u003C/strong> The second option is to create nest data based on a component prototype. Depending on the component's design, we can either manually measure or use more sophisticated optical measuring devices.\u003C/li>\u003Cli>\u003Cstrong>Existing tray:\u003C/strong> As a third option, we can reverse-engineer the data based on an existing tray prototype. Here, we measure the part with a Faro arm. A disadvantage is that imperfections on the tray's surface are also transferred to the data model. It is always important that other requirements, such as centering distances (for automated trays), grid dimensions, and desired measurements at the nest's bottom, are communicated. The more details are aligned in advance, the fewer errors will occur in the data construction.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Can I test the fit of the cavity before tool creation?\u003C/span>\u003C/h3>\u003Cp>Yes. Once the nest design has been created in the CAD program, its functionality can be tested with different variants (see also prototypes or our blog post on rapid prototyping).\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Options for testing mold nest samples\u003C/span>\u003C/h3>\u003Cp>Testing mold nest samples can be done with 3D printing or thermoforming from an Ureol tool.\u003C/p>\u003Cp>3D printing is the fastest option but provides less insight regarding the deep-drawing result. Thermoforming from an Ureol tool is slower but much more indicative, as it allows the direct transfer of learnings about the stretching behavior for the series.\u003C/p>\u003Cp>The appropriate option depends on the requirements profile, which consists of the following three factors:\u003C/p>\u003Cp>\u003Cstrong>Speed\u003C/strong>: How quickly are the samples and their review required?\u003C/p>\u003Cp>\u003Cstrong>Relevance\u003C/strong>: How comparable does the sample need to be to the series production? Does it need to use the original material and thickness? Should it be deep-drawn (tested method), or can an alternative method (3D printing) be used?\u003C/p>\u003Cp>\u003Cstrong>Effort\u003C/strong>: Is there a larger budget available for sample testing before starting production? Is it only the fit being tested, or should the tray be replicated as realistically as possible for series use\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What happens if the components do not fit in the mold nests?\u003C/span>\u003C/h3>\u003Cp>If the components do not fit in the cavities, mold nests can be quickly modified. We offer various sample levels that differ in speed, relevance, and effort.\u003C/p>\u003Cp>The 3D print and Ureol thermoforming sample options take advantage of naturally fast development times and are the quickest and most cost-effective options for fixed insights. After testing the samples with your components, adjustments can be made promptly.\u003C/p>\u003Cp>If adjustments are only noticed during the prototype's production or the first real handling tests, that's not a problem. The following guidelines apply:\u003C/p>\u003Ch3>Options for adjusting mold nests and cavities\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth style=\"border-bottom:1.0pt solid windowtext;border-left:1.0pt solid windowtext;border-right:1.0pt solid windowtext;border-top:1.0pt solid windowtext;padding:0cm 5.4pt;vertical-align:top;width:151.0pt;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>Tool design\u003C/strong>\u003C/span>\u003C/th>\u003Cth style=\"border-bottom:1.0pt solid windowtext;border-left:1.0pt none windowtext;border-right:1.0pt solid windowtext;border-top:1.0pt solid windowtext;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>Mold pockets can be adjusted in this direction  \u003C/strong>\u003C/span>\u003C/th>\u003Cth style=\"border-bottom:1.0pt solid windowtext;border-left:1.0pt none windowtext;border-right:1.0pt solid windowtext;border-top:1.0pt solid windowtext;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>Mold pockets cannot be adjusted in this direction\u003C/strong>\u003C/span>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:1.0pt solid windowtext;border-right:1.0pt solid windowtext;border-top:1.0pt none windowtext;padding:0cm 5.4pt;vertical-align:top;width:151.0pt;\">\u003Cstrong>Negative mold tool\u003C/strong>\u003C/td>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:none;border-right:1.0pt solid windowtext;border-top:none;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">\u003Cp>Deepen the mold nests\u003C/p>\u003Cul>\u003Cli>Increase the nest's size to create more space between the nest and the component\u003C/li>\u003Cli>Lower the nest to sink the components deeper into the nest\u003C/li>\u003C/ul>\u003C/td>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:none;border-right:1.0pt solid windowtext;border-top:none;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">Increase the nest height\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:1.0pt solid windowtext;border-right:1.0pt solid windowtext;border-top:1.0pt none windowtext;padding:0cm 5.4pt;vertical-align:top;width:151.0pt;\">\u003Cstrong>Positive mold tool\u003C/strong>\u003C/td>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:none;border-right:1.0pt solid windowtext;border-top:none;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">\u003Cp>Increase the nests\u003C/p>\u003Cul>\u003Cli>Tighten the mold nests around the component to reduce space between the component and the nest walls\u003C/li>\u003Cli>Raise the nest floor to position the components closer to the nest edge or even allow them to protrude (e.g., for better gripper positioning)\u003C/li>\u003C/ul>\u003C/td>\u003Ctd style=\"border-bottom:1.0pt solid windowtext;border-left:none;border-right:1.0pt solid windowtext;border-top:none;padding:0cm 5.4pt;vertical-align:top;width:151.05pt;\">Deepen the mold nests\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Determining mold nests and cavities - A conclusion\u003C/span>\u003C/h3>\u003Cp>The selection of appropriate mold nests for workpiece carriers is crucial for efficient transport and storage. Mold nests ensure that the component is securely held in the workpiece carrier and safely undergoes all production and logistics processes. In designing mold nests, cavities for gripper cutouts, as well as factors such as minimum distances, draft angles, and automation system requirements, should be considered. Overall, suitable mold nests are an essential component of product safety and process optimization.\u003C/p>\u003Cp>\u003Cstrong>Any questions? Contact us now via live chat or call: 07191 9525170.\u003C/strong>\u003C/p>","how-to-determine-tray-cavities",{"id":677,"documentId":678,"createdAt":679,"updatedAt":680,"publishedAt":681,"locale":10,"title":682,"introduction":683,"content":684,"slug":685},442,"nz5g6k8re0g3v1tfg9e9ppvl","2026-01-13T15:51:48.617Z","2026-01-26T08:36:28.367Z","2026-01-26T08:36:30.029Z"," 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",{"id":687,"documentId":688,"createdAt":689,"updatedAt":690,"publishedAt":691,"locale":10,"title":692,"introduction":693,"content":694,"slug":695},461,"xyw31v2kgt544xwab2ikmfhi","2026-01-13T15:51:52.175Z","2026-01-26T08:45:29.199Z","2026-01-26T08:45:30.349Z","Optimizing Intralogistics – How Trays Improve Your Intralogistics Processes","Rising customer demands, flexibility needs, and resource efficiency goals require companies to constantly improve intralogistics. To remain competitive and sustainable, they must optimize material flows, minimize handling times, and implement efficient storage and transport.","\u003Cp>Effective management of internal material and information flows helps save time, resources, and costs. In this context, trays play a crucial role in streamlining intralogistics operations.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Intralogistics?\u003C/span>\u003C/h2>\u003Cp>Intralogistics refers to the organization of all material and information flows within a company’s premises. It includes warehouse movements, inventory control, and internal goods transport but excludes external logistics processes such as distribution and delivery.\u003C/p>\u003Cp>Intralogistics covers the planning, execution, and optimization of internal material handling to ensure seamless operations and cost efficiency.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:19.14%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Prozesse_am_Laptop_um_die_Intralogistik_zu_optimieren_72f7d889ab.png\" alt=\"Prozesse, um die Intralogistik zu optimieren\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Key Components of Intralogistics\u003C/span>\u003C/h2>\u003Cp>The core tasks of intralogistics include:\u003C/p>\u003Cul>\u003Cli>Managing internal material and information flows\u003C/li>\u003Cli>Planning and executing internal transport processes\u003C/li>\u003Cli>Warehousing and inventory management\u003C/li>\u003Cli>Order picking and goods preparation\u003C/li>\u003Cli>Material flow control and optimization\u003C/li>\u003Cli>Implementation of conveyor systems and warehouse automation\u003C/li>\u003Cli>Process optimization for increased efficiency\u003C/li>\u003Cli>Integration of IT solutions for seamless workflow management\u003C/li>\u003C/ul>\u003Cp>Intralogistics relies on technologies such as warehouse management systems (WMS), automated material handling systems, robotics, data analytics, and artificial intelligence to optimize stock levels, route planning, and logistics processes.\u003C/p>\u003Cp>To enhance internal transport and storage efficiency, \u003Cstrong>plastic trays\u003C/strong> are widely used. Learn how deep-drawn trays contribute to intralogistics optimization in the following section.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Deep-Drawn Trays Optimize Your Intralogistics\u003C/span>\u003C/h2>\u003Cp>Optimized intralogistics processes focus on enhancing efficiency, ensuring smooth workflows, and reducing operational costs. Trays play a key role in achieving these goals:\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Schwarzes_Tray_mit_durchsichtigem_Deckel_zur_Intralogistik_Optimierung_db1150db2d.png\" alt=\"Schwarzes Tray mit durchsichtigem Deckel zur Intralogistik Optimierung\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Improved Transport and Handling\u003C/span>\u003C/h3>\u003Cp>Deep-drawn plastic trays, also known as \u003Cstrong>workpiece carriers\u003C/strong>, facilitate the internal transport of partially processed components, assemblies, or products within production facilities. They are designed to integrate seamlessly with conveyor systems and logistics workflows.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:16.95%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tray_mit_Griffmulden_c26e3d62b5.jpg\" alt=\"Tray with recessed grips\">\u003Cfigcaption>Tray with recessed grips\u003C/figcaption>\u003C/figure>\u003Cp>Trays with ergonomic grip recesses allow for easy manual or automated handling, reducing strain on workers and improving efficiency. Their lightweight construction simplifies transport and minimizes additional resource requirements.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Efficient Organization\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:14.54%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tray_mit_Farbstreifen_a0b7ab35d4.png\" alt=\"Tray mit Farbstreifen\">\u003Cfigcaption>Tray with color stripes\u003C/figcaption>\u003C/figure>\u003Cp>Plastic trays enable structured organization and sorting of products. Color-coded trays or labeled inserts enhance identification, reducing search times and errors in logistics operations.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Optimal Space Utilization\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:14.49%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Stapeltrays_8482098e51.jpg\" alt=\"Stapelbare Trays für die Optimierung der Intralogistik\">\u003Cfigcaption>Stackable trays\u003C/figcaption>\u003C/figure>\u003Cp>Stackable tray designs enable \u003Cstrong>space-saving storage\u003C/strong> in warehouses. Adjusting packaging densities (number of items per tray) helps streamline inventory processes.\u003C/p>\u003Cp>The \u003Cstrong>maximum packing density\u003C/strong> depends on specific application requirements, thermoforming constraints, and automation capabilities. By optimizing tray layouts, companies can maximize available space and improve logistics efficiency.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sustainability and Reusability\u003C/span>\u003C/h3>\u003Cp>Reusable plastic trays offer a \u003Cstrong>cost-effective and eco-friendly\u003C/strong> alternative to disposable packaging. Unlike single-use solutions, trays can be used multiple times, significantly reducing waste and lowering costs.\u003C/p>\u003Cp>Additionally, plastic trays are often \u003Cstrong>fully recyclable\u003C/strong>, allowing them to be processed into \u003Cstrong>recycled materials (regranulate)\u003C/strong> for further use.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Versatility and Customization\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:17.69%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Trays_als_Mehrwegverpackungen_d02b014c44.jpg\" alt=\"Trays als Mehrwegverpackungen\">\u003Cfigcaption>Trays as reuasable packaging\u003C/figcaption>\u003C/figure>\u003Cp>Plastic trays are available in various \u003Cstrong>sizes, shapes, and designs\u003C/strong> to meet specific industry requirements. They are widely used in sectors such as:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Automotive:\u003C/strong> Workpiece carriers for precision components\u003C/li>\u003Cli>\u003Cstrong>Electronics & Semiconductors:\u003C/strong> ESD trays for static-sensitive parts\u003C/li>\u003Cli>\u003Cstrong>Industrial Automation:\u003C/strong> Custom trays for robotic systems\u003C/li>\u003C/ul>\u003Cp>Whether for medical device transport, food storage, or industrial logistics, deep-drawn trays \u003Cstrong>offer flexible and customized solutions\u003C/strong> to optimize intralogistics processes.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Optimizing Intralogistics with Trays – A Conclusion\u003C/span>\u003C/h2>\u003Cp>Plastic trays play a critical role in \u003Cstrong>enhancing efficiency and sustainability\u003C/strong> in intralogistics. Their impact on safe and efficient storage and transport, along with their \u003Cstrong>reusability, versatility, and organizational benefits\u003C/strong>, makes them an essential part of modern logistics operations.\u003C/p>\u003Cp>Request your customized tray today via our configurator!\u003C/p>","optimizing-intralogistics",{"id":697,"documentId":698,"createdAt":699,"updatedAt":700,"publishedAt":701,"locale":10,"title":702,"introduction":703,"content":704,"slug":705},443,"p46qiqgsab5462kx1xih63sn","2026-01-13T15:51:48.797Z","2026-01-26T08:36:47.493Z","2026-01-26T08:36:48.209Z","SLC Inlays – The Optimal Solution for Transport and Storage","Small Load Carriers (SLCs) are widely used as transport and storage containers across various industries. Their functionality is enhanced by SLC Inlays, which protect delicate components, improve organization, and simplify handling. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are SLCs (Small Load Carriers)?\u003C/span>\u003C/h2>\u003Cp>\u003Cstrong>SLCs (Small Load Carriers)\u003C/strong> are standardized plastic containers used in logistics and manufacturing for the secure storage and transport of small parts. They are durable, stackable, and compatible with automated storage systems, simplifying any logistical process.\u003C/p>\u003Cp>\u003Cstrong>Types of SLC Containers:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>R-SLC (Returnable Small Load Carrier)\u003C/strong> – Sturdy container with a reinforced base, ideal for heavy loads and automated systems.\u003C/li>\u003Cli>\u003Cstrong>E-SLC (Ergonomic Small Load Carrier)\u003C/strong> – Designed with special grips for easier manual handling.\u003C/li>\u003Cli>\u003Cstrong>RL-SLC (Returnable Lightweight SLC)\u003C/strong> – A lighter version of the R-SLC for applications with lower weight requirements.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/KLT_6e5f4d4777.png\" alt=\"SLC container in blue \">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">SLC Inserts as the Perfect Addition to Small Load Carriers\u003C/span>\u003C/h2>\u003Cp>Euronorm containers are often used, but problems arise when components are transported as bulk goods and become damaged. To avoid this, suitable SLC inserts are required to secure the components. SLC inserts and inlays are customized container inserts, specially developed for SLCs and Euronorm containers using the plastic thermoforming process. They ensure structured, secure storage of components or parts that must not be handled as bulk goods. Container inserts can be used for any components, provided that they fit into the insert's slots.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of SLC Inserts:\u003C/span>\u003C/h2>\u003Cp>Container inserts offer numerous advantages in transport and warehousing. These include:\u003C/p>\u003Ch4>Perfect protection of components\u003C/h4>\u003Cp>Sensitive components require special protection. SLC inserts offer optimum fixation thanks to their precise fit and prevent components from colliding with each other or being damaged by movement.\u003C/p>\u003Ch4>More efficient processes\u003C/h4>\u003Cp>The use of container inserts facilitates handling in production and logistics. SLC inserts divide the interior into compartments for different components. The clear structuring of the components within the SLC speeds up picking and assembly, resulting in more efficient processes.\u003C/p>\u003Ch4>Protection against electrostatic discharge (ESD)\u003C/h4>\u003Cp>ESD inserts can be used for electronic components to protect them from electrostatic discharge. This is particularly important in the electronics and automotive industries. Find out more at ESD Trays.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Standard_ESD_Tiefzieheinlagen_aus_Kunststoff_frontal_012ce2ae90.png\" alt=\"Standard ESD-Tiefzieheinlagen aus Kunststoff_frontal\">\u003C/figure>\u003Ch4>Efficient use of space\u003C/h4>\u003Cp>The precise arrangement of the container inserts ensures optimum use of the available space in small load carriers and Euro containers.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Typical areas of application for SLC inserts\u003C/span>\u003C/h2>\u003Cp>SLC inserts are used in numerous branches of industry and contribute to increased efficiency in storage and transport logistics. In the automotive sector, they enable the safe storage and transport of screws, nuts, and other small parts.\u003C/p>\u003Cp>The electronics industry benefits from customized container inserts that protect sensitive components such as circuit boards and microchips from vibration. In medicine, sterile SLC inlays ensure hygienic storage of instruments and prevent contamination. The food industry also relies on special, food-safe container inserts that guarantee safe and hygienic packaging.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Overview of the areas of application for SLC inlays\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Industry\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Use Case for SLC Inserts\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Automotive\u003C/strong>\u003C/td>\u003Ctd>Organizing and protecting screws, nuts, and small parts\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Electronics\u003C/strong>\u003C/td>\u003Ctd>Safe transport of sensitive components (PCBs, microchips)\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Medical\u003C/strong>\u003C/td>\u003Ctd>Sterile storage of instruments and accessories\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Food Industry\u003C/strong>\u003C/td>\u003Ctd>Food-safe inserts for hygienic packaging\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion – Increased Efficiency with SLC Inserts\u003C/span>\u003C/h2>\u003Cp>From production to logistics and warehousing, SLC inserts significantly enhance the efficiency of \u003Cstrong>Small Load Carriers and Euro containers\u003C/strong>. They \u003Cstrong>improve protection, organization, and workflow efficiency\u003C/strong>—making them a must-have for any industry.\u003C/p>\u003Cp>Find the perfect SLC insert for your needs in our online shop!\u003C/p>","slc-inlays-solution-for-transport-storage",{"id":707,"documentId":708,"createdAt":709,"updatedAt":710,"publishedAt":711,"locale":10,"title":712,"introduction":713,"content":714,"slug":715},453,"tkf2zbtub4pco4i5rxtd08gt","2026-01-13T15:51:50.667Z","2026-01-26T08:42:06.522Z","2026-01-26T08:42:06.924Z","Construction Data in Thermoforming: These Factors Must Be Considered for Plastic Deep Drawn Parts","Deep drawn parts are custom-made and designed individually in a CAD format. Before a deep drawing tool is manufactured, a customer approval process of the CAD data or the derived, dimensioned PDF drawing takes place.","\u003Cp>This post explains the creation and approval process for the construction data of a plastic deep drawn part and highlights the key factors that are important for customer approval.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Creation of Construction Data in Thermoforming\u003C/span>\u003C/h2>\u003Cp>When talking about construction data in plastic thermoforming, we refer to the CAD (Computer-Aided Design) file or the derived, dimensioned drawing (often in PDF format) of the finished end product, which is the deep drawn part in this case. The creation of the data incorporates both customer requirements and Design for Manufacturing (DfM) recommendations from the thermoformer or tool manufacturer.\u003C/p>\u003Cp>These include everything from length dimensions to component-specific nesting geometries, material thicknesses, the assembly situation, and cutouts that will later be milled. These parameters are integrated into a deep-drawable design, with particular attention paid to radii and wall slopes. The design of the plastic deep drawn part serves as the foundation for creating the deep drawing tool from aluminum. Once the tool is created, the next step is the prototype approval.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Customer Requirements for Construction Data\u003C/span>\u003C/h2>\u003Cp>Usually, formary develops the product and, consequently, the construction data completely from scratch based on customer requirements. However, sometimes customers also provide ready-made CAD data of the deep drawn part. This happens either when the plastic deep drawn part already exists within the company and is being re-requested, or when the internal design department has created a proposal. In this case, we check the CAD data for Design for Manufacturability (DfM) and adjust them for deep drawability. The customer then reviews the data for correctness regarding the agreed requirements.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Format Should Your Construction Data Have?\u003C/span>\u003C/h2>\u003Cp>At formary, construction data is always provided to customers in the form of 2D drawings in PDF format and 3D data in STEP format (Standard for the Exchange of Product model data). The STEP format is a file type that enables the exchange of 3D models between CAD systems, regardless of which system the model was created on. The technical drawing includes detailed information about:\u003C/p>\u003Cul>\u003Cli>Textures\u003C/li>\u003Cli>Tolerances\u003C/li>\u003Cli>Material properties\u003C/li>\u003C/ul>\u003Cp>A precise and careful review of the construction data is crucial to ensure that the thermoformed parts meet the desired requirements in terms of functionality, quality, and design.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Key Factors in Reviewing Construction Data for Approval\u003C/span>\u003C/h2>\u003Cp>To ensure that the created deep draw design meets the requirements and guarantees functionality, the following factors must be carefully considered:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Dimensions\u003C/span>\u003C/h3>\u003Cp>The tolerance-compliant adherence to length dimensions (e.g., length x width x height) is always relevant to ensure that the final product meets the desired specifications. It should be checked whether the construction data were created with dimensional accuracy according to the agreed DIN ISO 2768 length measurement standard. A careful review of the data is significant to ensure successful prototyping through the manufactured tool.\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/Tiefzieh_Abdeckung_Abmessungen_26cbd7985c_1_46c01ef13b.jpg\" alt=\"Abmaße des Tiefzieh-Werkzeugs\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Nesting Geometry\u003C/span>\u003C/h3>\u003Cp>Nesting geometry is particularly crucial for transport solutions. The following questions must be addressed:\u003C/p>\u003Cul>\u003Cli>Are the components placed in the agreed orientation?\u003C/li>\u003Cli>Are the components picked up by the desired geometry to ensure safe transport along the planned route (factory, road, or rail)?\u003C/li>\u003Cli>Are handle recesses included for easy removal?\u003C/li>\u003Cli>Is the packing density as discussed?\u003C/li>\u003C/ul>\u003Cp>The construction data should therefore provide clear information on the conditions and tolerances that apply to the nesting geometry of the plastic deep drawn parts. This means the parts should be designed to make optimal use of the available space while ensuring smooth production flow.\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/sm_0068_bit_003_formary_50028_transport_5a6906c90d_1_41d10960f4.jpg\" alt=\"Nestergeometrie des Tiefziehteils\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Assembly Situation\u003C/span>\u003C/h3>\u003Cp>Covers require concrete data regarding the assembly situation. The assembly situation refers to the integration of the thermoformed part into the customer's overall product or assembly. When reviewing the construction data, it is important to consider the assembly situation to ensure that the part fits seamlessly into the intended environment and meets all assembly requirements. Therefore, questions like these are relevant:\u003C/p>\u003Cul>\u003Cli>Do the dimensions match the geometries where the cover will be fixed/assembled?\u003C/li>\u003Cli>Aspects such as the positioning of fasteners, tolerances for assembly, and ensuring compatibility with other components must be considered when reviewing the construction data in plastic thermoforming.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/sm_0024_bit_003_formary_50200_abdeckung_084035d392_1_92852eb019.jpg\" alt=\"Verbausituation der Tiefziehteile\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material and Material Starting Thickness\u003C/span>\u003C/h3>\u003Cp>Different plastics have different properties and are suitable for various applications, such as temperature resistance, hardness, UV protection, ESD protection, and chemical resistance. More information about different plastics can be found in the materials section.\u003C/p>\u003Cp>The material specified on the drawing should be checked for accuracy.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/md_kunststoff_granulat_9b0e2d4096_1_267ca762c0.jfif\" alt=\"Material und Materialausgangsstärke\">\u003C/figure>\u003Cp>The material starting thickness is also essential when reviewing the construction data. This refers to the thickness of the plastic sheet or roll used in thermoforming. The material starting thickness was determined during the quoting process based on technical criteria and can be compared with it.\u003C/p>\u003Cp>If multiple starting thicknesses are sampled to achieve the optimal stability and geometry result, the final construction drawing will be updated according to the chosen solution.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Process Flow for Creating and Reviewing Construction Data at formary\u003C/span>\u003C/h2>\u003Cp>The process for creating and reviewing construction data is as follows: Requirements - Design - Data Approval - Sample - Sample Approval - Production.\u003C/p>\u003Cp>In detail, the project planning for thermoforming is roughly divided into the following steps:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Request Your Project\u003C/span>\u003C/h3>\u003Cp>Enter your requirements in the configurator and send your inquiry to formary. You will receive an offer within 24 hours.\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/Tiefziehteil_anfragen_Laptop_Mockup_2b60f6315d.png\" alt=\"Projektanfrage\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Lassen Sie uns Ihre Daten erstellen\u003C/span>\u003C/h3>\u003Cp>In the second step, you have two options:\u003C/p>\u003Cul>\u003Cli>Do you have a design department? Then feel free to create your plastic deep drawn part yourself. You can consult our guide for the relevant parts of deep-drawable design. We will then review the drawing and adjust it for deep drawability.\u003C/li>\u003Cli>Would you like to have your plastic deep drawn part designed by experienced designers from the start? formary will create your data and design optimal geometries for thermoforming according to your requirements.\u003C/li>\u003C/ul>\u003Cp>formary creates your data and designs optimal geometries for thermoforming according to your requirements.\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/Datenfreigabe_Laptop_Mockup_und_Konstruktion_8347a0859b.png\" alt=\"Datenerstellung\">\u003C/figure>\u003Ch3>Receive Your Sample Quickly \u003C/h3>\u003Col>\u003Cli>Depending on your schedule, you will receive samples from the corresponding suitable option. There are 4 options, depending on the purpose of the samples:\u003C/li>\u003C/ol>\u003Cul>\u003Cli>Samples from 3D printed tool\u003C/li>\u003Cli>Samples from Ureol tool\u003C/li>\u003Cli>Samples from partial segment series tool\u003C/li>\u003Cli>Samples from series tool\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Werkzeug_und_Bemusterung_cd0eff947f.png\" alt=\"Samplesanfrage\">\u003C/figure>\u003Cp> \u003C/p>\u003Ch3>We Start Your Series Production \u003C/h3>\u003Cp>After successful sampling, we will start series production. Depending on your material, the chosen tool design, the type of machine used for manufacturing, and the quantity, the lead time is approximately 3-5 weeks from approval/order receipt to delivery of your series.\u003C/p>\u003Ch2>Conclusion: Quality Assurance in Thermoforming Through Thorough Review of Construction Data\u003C/h2>\u003Cp>Construction data for the thermoformed part is not only created for tool manufacturing but also primarily for customer approval of the end product. At this stage, any additional or previously overlooked requirements can be easily identified and incorporated into the design. This ensures an efficient prototyping and project process. formary ensures that a competent contact person is available throughout the project to clarify any questions. Try it yourself and request your plastic deep drawn part digitally.\u003C/p>","construction-data-in-thermoforming",{"id":717,"documentId":718,"createdAt":719,"updatedAt":720,"publishedAt":721,"locale":10,"title":722,"introduction":723,"content":724,"slug":725},423,"eozo3dmd50mtvypvxw59tzjd","2026-01-13T15:51:44.989Z","2026-01-26T08:27:27.147Z","2026-01-26T08:27:27.188Z","Plastic Extrusion: How Plastic Film is Made","Plastic extrusion is a highly efficient manufacturing process that transforms plastic granules into continuous film. This versatile material is used across various industries, tailored to specific applications and performance requirements.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Plastic Extrusion?\u003C/span>\u003C/h2>\u003Cp>\u003Cstrong>Meaning of Extrusion:\u003C/strong> Plastic extrusion is a molding process used to create plastic products. The extrusion of plastic is achieved by shaping and melting plastic granules. Plastic granules, also known as plastic pellets or plastic flakes, are a common starting form of plastics. \u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:12.69%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffflakes_e0e0065308.png\" alt=\"Kunststoffgranulat\">\u003Cfigcaption>Plastic flakes: Thinner, flat pieces of plastic\u003C/figcaption>\u003C/figure>\u003Cp>These are small, granular particles made from various types of thermoplastic materials. These particles typically have a consistent size and shape, making them ideal for use in industrial manufacturing processes. During plastic extrusion, the granules or powder are forced through a shaping nozzle to achieve the desired form.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is an Extruder?\u003C/span>\u003C/h2>\u003Cp>The extruder ensures that the molten plastic flows into an elongated, thin form known as melt strands. After cooling and hardening, the strand is cut into small granular pieces – the finished granules – which are then collected and stored in bags, big packs, or containers.\u003C/p>\u003Cp>These granules are then either processed in injection molding machines or again in the extruder. The latter applies to plastic sheets and films.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Materials are Suitable for Plastic Extrusion?\u003C/span>\u003C/h2>\u003Cp>Manufacturers of plastic films or sheets first purchase the necessary granules. The material depends on the type of plastic film being processed. For PET films, PET granules are required. Additionally, a distinction is made between using \"virgin\" (new) material or recycled material (regranulate). When manufacturing regranulate films, flakes are fed into the extruder.\u003C/p>\u003Cp>\u003Cstrong>These plastic flakes are thinner, flat pieces of plastic.\u003C/strong> Unlike granules, flakes do not have a regular shape or size. They are often produced by recycling used plastic items such as plastic bottles that are crushed and cleaned or die-cut grids, or edge strips that are further ground in the machine.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Plastics Can Be Extruded?\u003C/span>\u003C/h2>\u003Cp>Various types of plastics can be used in plastic extrusion, such as:\u003C/p>\u003Cul>\u003Cli>Polyethylene (PE)\u003C/li>\u003Cli>Polypropylene (PP)\u003C/li>\u003Cli>Polyethylene Terephthalate (PET)\u003C/li>\u003Cli>Polystyrene (PS)\u003C/li>\u003Cli>Polycarbonate (PC)\u003C/li>\u003Cli>Acrylonitrile-Butadiene-Styrene Copolymer (ABS)\u003C/li>\u003Cli>Bioplastics.\u003C/li>\u003C/ul>\u003Cp>The choice of material depends on the desired properties of the plastic film, such as transparency, flexibility or rigidity, or resistance to external factors like heat, cold, UV resistance, etc.\u003C/p>\u003Cp>For more details on the properties of different plastics, please visit the \"Materials\" section.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does Plastic Extrusion Work? Manufacturing Plastic Films\u003C/span>\u003C/h2>\u003Cp>In plastic extrusion, thermoplastic plastics are transformed from granules into semi-finished products like films or thicker sheets. Semi-finished products refer to materials in their simplest form. In the following sections, the plastic extrusion process and its functionality are explained in detail.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Feeding the Raw Material\u003C/span>\u003C/h3>\u003Cp>The raw material, in the form of granules or flakes, is fed into the plastic extruder through a hopper.\u003C/p>\u003Cp>Depending on the desired properties of the plastic film, additives like colorants, stabilizers, or additives (e.g., for ESD or flame retardance) can be added.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Schmelzen und Homogenisieren des Kunststoffs\u003C/span>\u003C/h3>\u003Cul>\u003Cli>The granules are melted and homogenized in the electrically heated cylinder of the extruder.\u003C/li>\u003Cli>A screw inside the extruder ensures the flow of the molten material and mixes the materials.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Extruder Setup\u003C/span>\u003C/h3>\u003Cp>The setup of the extruder varies depending on the material being processed:\u003C/p>\u003Cul>\u003Cli>Horizontal nozzles (with or without dust bars) are used for viscous melts.\u003C/li>\u003Cli>Vertical nozzles are used for thin liquids like PET.\u003C/li>\u003Cli>Plate systems have a completely different setup with varying cooling paths.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Shaping the Plastic Film\u003C/span>\u003C/h3>\u003Cul>\u003Cli>The molten plastic exits the extruder as a strand-like melt and is pressed into the die using a melt pump.\u003C/li>\u003Cli>The die forms the melt into a thin layer, which is the precursor to the plastic film.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Smoothing and Finalizing the Film\u003C/span>\u003C/h3>\u003Cp>The formed layer is guided through a smoothing station with heated rollers to ensure a consistent material thickness.\u003C/p>\u003Cp>The material strip is then trimmed to the desired width using a single or multi-cut system.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What Happens to the Plastic Film After Plastic Extrusion?\u003C/span>\u003C/h3>\u003Cp>After the cooling section, the plastic film undergoes further processing. This may include printing specific information or designs on the plastic film. Additional processing steps may also involve laminating with other materials or applying coatings.\u003C/p>\u003Cp>The final product is then wound into rolls, or for thicker sheets, it is cut to the desired width and length using a separator saw or shear.\u003C/p>\u003Cp>he extruded plastic rolls or sheets serve as raw materials for producing thermoformed parts, among other things. For thermoforming, semi-finished products are heated and drawn into a mold. The semi-finished products are either unwound from a plastic roll or placed in the machine as a plastic sheet.\u003C/p>\u003Cp>For plastic rolls, the maximum starting thickness is 3mm, though many manufacturers limit it to 2.5mm due to the difficulty of winding the film to this thickness. Beyond this, the semi-finished product becomes too rigid for processing and is instead cut into sheets.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Applications of Plastic Film\u003C/span>\u003C/h3>\u003Cp>Plastic film is a highly versatile product with a wide range of applications. We focus on plastic film as a thermoformed part, where it is used across various industries:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Automotive\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Medical and Pharmaceutical\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Mechanical Engineering\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Industry\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Electronics and Semiconductor Technology\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Consumer Goods\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Food\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Cosmetics\u003C/strong>\u003C/li>\u003C/ul>\u003Cp>The applications are described in more detail below. You can find more information on the application of plastic film and its processing options in the following video.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Ciframe width=\"560\" height=\"315\" src=\"https://www.youtube.com/embed/2_KRmNsF1Gw?si=wF4k0y1oAsk0lU1U\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen=\"\">\u003C/iframe>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive Industry\u003C/span>\u003C/h3>\u003Cp>In the automotive industry, plastic films are used in transportation and storage logistics as thermoformed packaging solutions and reusable trays. The film thickness in such applications ranges from 0.2 to 0.8 mm.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:15.31%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Verpackungsloesungen_und_Mehrwegtrays_in_der_Automobilbranche_8b276ac952.png\" alt=\"Kunststofffolien als Transportlösungen und Mehrwegtrays in der Automobilindustrie\">\u003Cfigcaption>Plastic films as transport solutions and reusable trays in the automotive industry\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Medical and Pharmaceutical\u003C/span>\u003C/h3>\u003Cp>High hygiene standards are crucial in the medical field. Sterilizable and biocompatible materials are essential. Thermoformed parts, such as trays, inserts, and medical blisters, are used for packaging small medical items like syringes and needles.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:23.24%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Medizinblister_in_der_Medizinbranche_678ce76d4e.png\" alt=\"Nutzung von Kunststofffolien als Medizinblister in der Medizin\">\u003Cfigcaption>Use of plastic films as medicine blister packs in the medical industry\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Mechanical Engineering\u003C/span>\u003C/h3>\u003Cp>Plastic films with ESD protection and electrical insulating properties are used as thermoformed machine covers for sensitive machine parts.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industry\u003C/span>\u003C/h3>\u003Cp>In industry, plastic films are used as thermoformed containers for chemicals and liquids, as well as for casting molds or covers.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.74%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefgezogene_Behaeltnisse_in_der_Industrie_f64d0cabb8.png\" alt=\"Kunststofffolien als tiefgezogene Behältnisse oder Vergussformen in der Industrie\">\u003Cfigcaption>Plastic films as deep-drawn containers, covers, and molds in industry\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Electronics and Semiconductor Technology\u003C/span>\u003C/h3>\u003Cp>To ensure the safe transport of electrostatically sensitive components like semiconductors, circuits, or diodes, plastic films are used as thermoformed ESD workpiece carriers and ESD transport packaging. These specialized packaging solutions are designed to prevent electrostatic discharges and protect the components during shipping.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Consumer Goods\u003C/span>\u003C/h3>\u003Cp>In the consumer goods sector, transparent plastic films are used as thermoformed packaging for retail and e-commerce. These clear packaging solutions allow for a visible display of the product while providing protection and security.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:21.89%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoff_Sichverpackungen_fuer_Konsumgueter_Industrie_76878c9c19.png\" alt=\"Sichtverpackungen für Konsumgüter-Industrie\">\u003Cfigcaption>Plastic films as display packaging for consumer goods\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Food\u003C/span>\u003C/h3>\u003Cp>Plastic films are used as primary packaging in the food industry, ensuring freshness and hygiene for perishable food items. They are often sealed with a protective film to preserve food quality and protect it from external influences. Thermoformed plastic trays are used for the safe transport of delicate food items.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Cosmetics\u003C/span>\u003C/h3>\u003Cp>In the beauty industry, thermoformed parts are frequently used as secondary packaging in retail. Transparent materials and optimal product fit are essential for creating attractive packaging designs, while ensuring product protection during transport.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:21.37%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Blisterverpackungen_fuer_Kosmetikindustrie_90baaf45ba.png\" alt=\"Blisterverpackungen für Kosmetikindustrie\">\u003Cfigcaption>Plastic films as blister packaging for the cosmetics industry\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic Extrusion with the formary Supplier Network\u003C/span>\u003C/h2>\u003Cp>In most cases, thermoformers buy the required plastic film. However, some suppliers in the formary network extrude their own thermoforming film in-house. This in-house extrusion offers several benefits:\u003C/p>\u003Cul>\u003Cli>Tailored solutions to meet customer needs (material properties, additives, colors).\u003C/li>\u003Cli>Better control over product quality, ensuring the film has the desired properties.\u003C/li>\u003Cli>Optimized production processes and increased efficiency due to deeper value creation.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion\u003C/span>\u003C/h2>\u003Cp>Plastic extrusion is an essential process for the production of plastic films. Thanks to their diverse properties and areas of application, thermoformed parts made from plastic films are indispensable in numerous industries. Does your industry require thermoforming films in order to benefit from the above-mentioned properties?  Then configure your thermoforming product now.\u003C/p>","plastic-extrusion",{"id":727,"documentId":728,"createdAt":729,"updatedAt":730,"publishedAt":731,"locale":10,"title":732,"introduction":733,"content":734,"slug":735},455,"u2oehuqlrx0hg9j751fu67kg","2026-01-13T15:51:51.054Z","2026-01-26T08:43:06.837Z","2026-01-26T08:43:07.096Z","Thermoformed Plastic Parts in Use – Detailed Applications","Thermoformed plastic parts play a crucial role in almost every industry, from manufacturing and mechanical engineering to medicine and food production. In this article, we take a closer look at the various applications of thermoformed plastic parts across different industries.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are Thermoformed Plastic Parts?\u003C/span>\u003C/h2>\u003Cp>Thermoformed plastic parts are products created through plastic thermoforming, also known as vacuum forming. This process allows thermoformable plastics to be molded into nearly any shape, making it an ideal solution for a wide range of products and applications.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Applications of Thermoformed Plastic Parts\u003C/span>\u003C/h3>\u003Cp>Thermoformed plastic parts are used in various industries, including:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Automotive\u003C/strong>: Body components and other parts\u003C/li>\u003Cli>\u003Cstrong>Electronics\u003C/strong>: Housing components\u003C/li>\u003Cli>\u003Cstrong>Consumer Goods & Food\u003C/strong>: Packaging solutions\u003C/li>\u003Cli>\u003Cstrong>Logistics\u003C/strong>: Secure transport pallets for different components\u003C/li>\u003C/ul>\u003Cp>Depending on the application, the focus of plastic parts can vary. As standalone product components, aesthetics and functionality are key. When used as transport or \u003Ca href=\"https://www.formary.de/en/products/thermoformed-plastic-packaging\">packaging \u003C/a>materials, protection during shipping and production takes priority.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:31.84%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Schutzabdeckung_203c671390.png\" alt=\"Kunststoff Motorabdeckung\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Properties of Thermoformed Plastic Parts\u003C/span>\u003C/h2>\u003Cp>Thermoformed plastic parts can be tailored with different material properties, making them suitable for diverse industries. Key properties include:\u003C/p>\u003Cul>\u003Cli>ESD protection\u003C/li>\u003Cli>Cleanroom hygiene\u003C/li>\u003Cli>Sterility\u003C/li>\u003Cli>Food-grade compliance\u003C/li>\u003Cli>High-quality appearance for product presentations\u003C/li>\u003C/ul>\u003Cp>These characteristics are especially crucial in the medical and electronics industries. Popular thermoforming materials include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>PVC\u003C/strong>: Durable and versatile\u003C/li>\u003Cli>\u003Cstrong>PET-A\u003C/strong>: Transparent and cost-effective\u003C/li>\u003Cli>\u003Cstrong>ABS\u003C/strong>: Strong mechanical and thermal properties\u003C/li>\u003Cli>\u003Cstrong>PS\u003C/strong>: A standard reference plastic for thermoforming\u003C/li>\u003Cli>\u003Cstrong>PP (Polypropylene)\u003C/strong>: Chemical resistance and lightweight\u003C/li>\u003C/ul>\u003Cp>In our video series, we demonstrate which thermoplastics are best suited for specific applications.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Ciframe width=\"560\" height=\"315\" src=\"https://www.youtube.com/embed/videoseries?si=hbskpImmmIjaH5P_&list=PLDxs2h_LTCGB9M2D6a_O2eFk8lGkOGk3L\" title=\"„YouTube-Videoplayer“\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen=\"\">\u003C/iframe>\u003C/div>\u003Cp>\u003Cstrong>Want to compare plastic with metal?\u003C/strong> Read our article: \u003Cstrong>Plastic vs. Metal – A Comparison\u003C/strong>.\u003C/p>\u003Ch3>Transport & Storage\u003C/h3>\u003Cp>Thermoformed plastic parts play a crucial role in logistics. \u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:10.13%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefgezogenes_Transport_Tray_in_weiss_5400cae21f.jpg\" alt=\"Transport Tray in weiß\">\u003Cfigcaption>Transport Tray in white\u003C/figcaption>\u003C/figure>\u003Cp>\u003Cstrong>Transport trays and workpiece carriers\u003C/strong> are open plastic thermoformed packaging solutions that protect components throughout the supply chain. Examples include:\u003C/p>\u003Cul>\u003Cli>Load carriers for the \u003Cstrong>automotive industry\u003C/strong>\u003C/li>\u003Cli>Tray packaging for \u003Cstrong>metal parts\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>ESD workpiece carriers\u003C/strong> for electronics\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automation & Production\u003C/span>\u003C/h3>\u003Cp>Thermoformed plastic parts are essential for modern manufacturing. \u003Cstrong>Automation trays\u003C/strong> allow for efficient handling of components in production lines. These custom-molded trays feature designed form nests and stacking methods, enabling automated robotic handling.\u003C/p>\u003Cp>Trays can be designed to accommodate multiple manufacturing phases, ensuring seamless integration into the \u003Cstrong>production process\u003C/strong>.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Inlays & Inserts\u003C/span>\u003C/h3>\u003Cp>Inlays and inserts are used in storage systems such as \u003Cstrong>cases, drawers, and packaging\u003C/strong> to securely hold components. \u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:16.45%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Inlay_in_schwarz_4638810121.jpg\" alt=\"Inlay in schwarz\">\u003Cfigcaption>Inlay in black\u003C/figcaption>\u003C/figure>\u003Cp>Common uses include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Packaging inlays\u003C/strong>\u003C/li>\u003Cli>\u003Cstrong>Plastic drawer inserts\u003C/strong>\u003C/li>\u003C/ul>\u003Cp>Thermoformed plastic inlays are \u003Cstrong>scratch-resistant and resistant to cleaning agents\u003C/strong>. They can also be customized to match \u003Cstrong>corporate identity (CI) guidelines\u003C/strong>, enhancing product presentation.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Covers & Housings\u003C/span>\u003C/h3>\u003Cp>Plastic covers are ideal for \u003Cstrong>protecting sensitive equipment and machinery\u003C/strong>. \u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:9.78%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffabdeckung_transparent_951230831a.jpg\" alt=\"Transparente Kunststoffabdeckung\">\u003Cfigcaption>Transparent plastic cover\u003C/figcaption>\u003C/figure>\u003Cp>They shield against \u003Cstrong>dust, moisture, and damage\u003C/strong>, while also enhancing aesthetics by concealing cables and components.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Examples of Cover & Housing Applications\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Outdoor Applications\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Indoor Applications\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Exterior casings\u003C/td>\u003Ctd>Covers for electronic devices\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Wheel arches & construction machinery covers\u003C/td>\u003Ctd>Motor covers\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Cable ducts & covers\u003C/td>\u003Ctd>Distribution housings\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Enclosures for switch cabinets\u003C/td>\u003Ctd>Protective housings for instruments\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Climate control system enclosures\u003C/td>\u003Ctd>Security & alarm system casings\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Containers & Trays\u003C/span>\u003C/h3>\u003Cp>Thermoformed plastic containers include \u003Cstrong>plant trays, paint trays, and casting molds\u003C/strong>. These products require:\u003C/p>\u003Cul>\u003Cli>High shape stability\u003C/li>\u003Cli>Ergonomic handling\u003C/li>\u003Cli>Precise fit & durability\u003C/li>\u003C/ul>\u003Cp>For outdoor use, materials like \u003Cstrong>ABS and ASA\u003C/strong> are preferred due to their \u003Cstrong>UV resistance\u003C/strong>.\u003C/p>\u003Cp>For more information, check out our design guidelines for thermoformed plastic parts!\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion – Thermoformed Plastic Parts Offer Endless Possibilities\u003C/span>\u003C/h2>\u003Cp>Thermoformed plastic parts are \u003Cstrong>highly versatile\u003C/strong> and adaptable to your \u003Cstrong>specific needs\u003C/strong>. Whether for handling, presentation, or \u003Cstrong>protecting products and components\u003C/strong>, they provide \u003Cstrong>an ideal solution\u003C/strong>.\u003C/p>\u003Cp>\u003Cstrong>Need customized thermoformed parts?\u003C/strong> Request a quote today!\u003C/p>\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>ℹ️ Want to stay up to date with the latest news from the thermoforming industry and formary? Then subscribe to our \u003Ca href=\"https://landing.formary.de/newsletter-anmeldung\">newsletter!\u003C/a>\u003C/p>\n\u003C/div>\u003C/div>","applications-of-thermoformed-parts",{"id":737,"documentId":738,"createdAt":739,"updatedAt":740,"publishedAt":741,"locale":10,"title":742,"introduction":743,"content":744,"slug":745},428,"ijlrusckxsm6mygyyu1hkehr","2026-01-13T15:51:45.925Z","2026-01-26T08:29:40.497Z","2026-01-26T08:29:40.943Z","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":747,"documentId":748,"createdAt":749,"updatedAt":750,"publishedAt":751,"locale":10,"title":752,"introduction":753,"content":754,"slug":755},422,"dgjboddl2fyoljil9zl9btkp","2026-01-13T15:51:44.762Z","2026-01-26T08:26:45.867Z","2026-01-26T08:26:45.906Z","Plastic retainers in Industry – Common Mistakes and How to Avoid Them","Industrial plastic retainers must withstand mechanical, chemical, and long-term stresses. They are designed to support your processes and employees.","\u003Cp>Ideally, a deep-drawn plastic tray and container are robust, have a long lifespan, and fit well.\u003C/p>\u003Cp>We show you how to avoid cracks and improper handling with your plastic tray to extend its lifespan.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What does Ergonomics Have to Do with Plastic Trays?\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:10.9%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefzieh_Behaeltnis_Griffmulden_4fa4175c3f.jpg\" alt=\"Griffmulden bei Kunststoffwannen\">\u003C/figure>\u003Cp>With deep drawn plastic trays, the key questions are: What purpose will they serve, and how heavy will they be when filled? Plastic trays are carried from machine to assembly station or lifted out of packaging, KLTs (small load carriers), and boxes.\u003C/p>\u003Cp>Keep in mind that for ergonomic handling, weight and feel need to be considered. According to occupational health specialists, even lifting weights of 25 kg for women and 40 kg for men can pose health risks if done just once. For this reason, we ensure that your plastic tray is loaded with a maximum of 14 kg or 35 kg when handled by two people.\u003C/p>\u003Cp>In addition to maximum weight, your employees can be assisted with lifting, carrying, and placing plastic trays through support systems. Handles or grip indentations must be sufficiently stable and positioned to account for the tray's center of gravity when filled.\u003C/p>\u003Cp>An ergonomic design adapts to the anatomy of the hand. The grip should be able to be fully wrapped by the hand, providing a comfortable, secure grip without wobbling. Any feeling of insecurity during handling should be avoided, and the tray itself must be stable.\u003C/p>\u003Cp>How critical areas are stabilized will be explained in the next section.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Avoiding Bends, Cracks, and Warping in Plastic Trays\u003C/span>\u003C/h2>\u003Cp>Plastic trays that bend or break when lifted create frustration at work. But where do bends and cracks in plastic come from? Plastic damage usually occurs due to:\u003C/p>\u003Cul>\u003Cli>The load weight not being considered in the plastic design.\u003C/li>\u003Cli>The plastic failing to withstand sharp or pointed loads.\u003C/li>\u003Cli>The plastic tray being used for too long.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Can Plastic Trays Be Designed as Reusable Products?\u003C/span>\u003C/h3>\u003Cp>Absolutely. Whenever possible, we strive to design plastic trays as reusable products because longevity is both economically and ecologically beneficial.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic Trays – Key Criteria for Longevity\u003C/span>\u003C/h2>\u003Cul>\u003Cli>How long will the plastic tray be in use?\u003C/li>\u003Cli>What will it be used for, and what will it carry?\u003C/li>\u003Cli>What are the load-bearing values in kilograms?\u003C/li>\u003Cli>Is it exposed to additional mechanical stress from the surroundings or contents?\u003C/li>\u003C/ul>\u003Cp>Your plastic trays are equipped with reinforcement structures. We can add ribs, braces, or transition contours, use thicker base materials, and optimize the forming ratio and material distribution. Our experts will select the right material and, most importantly, the right material thickness for you. We focus on meeting your needs in a material-efficient way. Learn more in our design rules for plastic deep-drawn parts.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Special Applications of Plastic Trays\u003C/span>\u003C/h2>\u003Cp>\u003Cstrong>Custom Milling of Plastic Trays\u003C/strong>\u003C/p>\u003Cp>Custom milling on the bottom of the tray\u003C/p>\u003Cp>The use of plastic trays in industry is as diverse as the industry itself. From containment trays to washing and cleaning trays, and even food-safe containers, the possibilities are endless. A small sample of construction options:\u003C/p>\u003Cul>\u003Cli>Special openings and cutouts can be added to the bottom for specific requirements.\u003C/li>\u003Cli>Connection systems to surrounding objects can be added.\u003C/li>\u003Cli>Tight tolerances? These can be maintained at critical points in the deep-drawing tool.\u003C/li>\u003Cli>Sensitive glossy trays can be specially packaged with film and intermediate layers to prevent scratches during transport and storage.\u003C/li>\u003C/ul>\u003Cp>If you want to further protect the contents of the tray or prepare it for transport, a suitable lid is essential.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Plastic Lid Must Primarily Fit – Both the Plastic Tray and Your Application\u003C/span>\u003C/h2>\u003Cp>The lid is designed to seal the plastic tray, which serves various purposes, particularly in industries like food or pharmaceuticals where hygiene standards are crucial. The lid protects the contents from:\u003C/p>\u003Cul>\u003Cli>Dust\u003C/li>\u003Cli>Contamination\u003C/li>\u003Cli>Particles\u003C/li>\u003C/ul>\u003Cp>Additionally, both the plastic tray and the lid must endure sterilization, temperature resistance, and chemical resistance. Many other industries share these requirements, especially when handling sensitive, high-tech parts or transporting chemicals.\u003C/p>\u003Cp>Plastic lids serve more purposes than simply protecting the contents. They can also prevent leaks or spills and serve as a stacking and interlocking system for storage and interim storage. It’s important to ensure the contents of the tray do not protrude over the lid. The tray's load should be fully submerged or level with the edge of the tray. Various sealing techniques can be used to prevent the lid from opening.\u003C/p>\u003Cp>Depending on requirements, a plastic closure can be: loose-fitting, easy to remove → lid with clip closure held in place on the plastic tray with a plug-in mechanism → lid with pressure closure fixed to the plastic tray with hinges so that it can be opened and closed → lid with hinge. If the lid is made of transparent plastic, it provides sufficient visibility so that you can ensure that the contents are intact.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Avoiding Common Mistakes with Plastic Trays – Key Takeaways\u003C/span>\u003C/h2>\u003Cp>To extend the lifespan of your plastic trays and avoid damage, pay attention to proper handling, use stable carrying handles, and monitor the load weight. Additionally, custom adjustments such as reinforcement structures and special packaging can help increase stability and protect the contents. In summary, plastic trays are highly durable and can survive many production cycles when handled properly.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Requesting the Right Product – Quickly Getting to the Perfect Solution\u003C/span>\u003C/h3>\u003Cp>Get your custom rectangular, round, or shape-specific plastic container now. Click on \"Containers\" in the formary configurator. formary will ask for all relevant information. Still have questions or something to discuss?\u003C/p>\u003Cp>Write to us in the LiveChat or call: \u003Cstrong>+497191 9525170.\u003C/strong>\u003C/p>","plastic-retainers-common-mistakes",{"id":432,"documentId":757,"createdAt":758,"updatedAt":759,"publishedAt":760,"locale":10,"title":761,"introduction":762,"content":763,"slug":764},"ipuvt9l41d8xu1pvb1u40off","2026-01-13T15:51:46.283Z","2026-01-26T08:31:09.992Z","2026-01-26T08:31:10.042Z","Supplier Guide for Plastic Thermoformed Parts – 10 Key Factors That Matter","Choosing the right supplier for plastic thermoformed parts is crucial for the quality, efficiency, and cost-effectiveness of your production. Our 10 tips will show you what to look for when selecting a supplier.","\u003Ch2>\u003Cspan style=\"color:#005250;\">10 Key Factors to Consider When Choosing a Supplier for Plastic Thermoformed Parts\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Are you planning to switch suppliers or looking for the right partner for a new thermoforming project? Do you want to ensure you select the right manufacturer and avoid past mistakes? We have summarized the 10 most important criteria for choosing a supplier for plastic thermoformed parts.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Technological Abilities\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:23.66%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Technologische_Faehigkeiten_bei_Lieferanten_7fba251155.png\" alt=\"Technologische Fähigkeiten bei Lieferanten\">\u003C/figure>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastic thermoforming has many applications and end products. Ensure that the supplier has the right machine types (roll-fed, sheet-fed), machine components (frames, punching stations), and manufacturing processes (vacuum, pressure forming) for your product.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Material Availability\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In plastic processing, selecting the right material and ensuring its availability are crucial. Determine whether the supplier is equipped for the material in question and has expertise in processing challenging materials (such as PP).\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Does the supplier keep the material in stock, or does it need to be sourced separately? Some suppliers extrude their own plastic, making them independent of market prices and enabling faster, more efficient production.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Experience & Expertise\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastic processing involves a wide range of material requirements, geometries, trimming and post-processing techniques, and quality standards. Industries such as medical and automotive have specific requirements and regulations, such as cleanroom manufacturing, that require specialized experience and expertise.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Professional, Long-Term Support\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastic thermoformed parts are often developed in collaboration with the thermoformer or their toolmaking department based on your product requirements. As a non-expert in thermoforming, you need comprehensive information, professional advice, and guidance on potential risks and how to mitigate them.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Post-Processing Capabilities\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:24.19%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Nachbearbeitungsverfahren_3296c30b37.png\" alt=\"Nachbearbeitungsverfahren als Kriterium für die Lieferantensuche\">\u003C/figure>\u003Cp>Effective post-processing—ranging from milling and punching to assembly and surface finishing—is a key criterion when selecting a supplier. A good supplier has the necessary machines and expertise or a reliable network to outsource specific steps.\u003C/p>\u003Cp>Since plastic parts are often classified as B- or C-parts, buyers should look for suppliers that offer all services from a single source. Otherwise, increased effort, delivery delays, and quality issues due to additional transport and coordination may arise.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">6. Capacity & Lead Times\u003C/span>\u003C/h3>\u003Cp>Planning reliability is essential. Check whether the supplier has:\u003C/p>\u003Cul>\u003Cli>Sufficient machine capacity\u003C/li>\u003Cli>Reliable delivery schedules with regular updates\u003C/li>\u003C/ul>\u003Cp>A reliable supplier provides the necessary production capacity and continuously expands it with a modern machine fleet as needed.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">7. Price-Performance Ratio\u003C/span>\u003C/h3>\u003Cp>Prices for plastic parts can vary significantly between suppliers, often due to opaque cost structures. Price differences may stem from factors such as machine compatibility, tool components, material availability, stock levels, and whether post-processing is done in-house or outsourced.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">8. Quality Assurance\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:16.82%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Ein_Mann_der_ein_Dokument_abstempelt_0e862d452f.png\" alt=\"Qualitätssicherung bei der Lieferantensuche\">\u003C/figure>\u003Cp>A supplier with a robust quality assurance system reduces complaints and eases your incoming goods inspection. Plastic parts require tooling and sample approval, where fast turnaround times and optimal quality are critical.\u003C/p>\u003Cp>Does the supplier have the necessary ISO certifications for the product or target market? Do they have trained personnel, measurement tools, and machines to provide the required test reports?\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">9. Certifications & Tolerances\u003C/span>\u003C/h3>\u003Cp>Pay special attention to certifications such as ISO 9001 and other industry-specific standards required for your end product or market. Maximum tolerances for manufacturing are especially important for technical plastic parts, such as housings and trays used in automated systems.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">10. Security & Trust\u003C/span>\u003C/h3>\u003Cp>Plastic thermoforming requires an investment in forming tools designed specifically for the supplier’s machinery. Therefore, choosing a supplier should be based on a long-term partnership built on security and trust. Check whether:\u003C/p>\u003Cul>\u003Cli>The supplier is willing to sign an NDA\u003C/li>\u003Cli>Your 3D data and design drawings are adequately protected\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Why formary is the Right Supplier for Your Plastic Parts\u003C/span>\u003C/h3>\u003Cp>With formary, you gain access to a nationwide network of over 70 plastic thermoforming manufacturers in Germany. This supplier network provides you with unlimited production capacities and all thermoforming processes, including post-processing. The formary algorithm matches your product with the specialized supplier best suited for your needs.\u003C/p>\u003Cp>You are 100% guaranteed:\u003C/p>\u003Cul>\u003Cli>Industry-specific experience and certifications\u003C/li>\u003Cli>A machine fleet tailored to your requirements\u003C/li>\u003Cli>Full-service solutions for all post-processing steps\u003C/li>\u003Cli>Competitive pricing through cost-efficient manufacturing\u003C/li>\u003Cli>Product-specific expertise\u003C/li>\u003Cli>Production capacities that meet your required lead times and quantities\u003C/li>\u003C/ul>\u003Cp>formary reduces your procurement effort for plastic parts through intelligent, fast, and efficient processes. Simply submit your request via our online configurator—we take care of the rest. Get your quote now!\u003C/p>","supplier-guide-for-plastic-thermoformed-parts",{"id":462,"documentId":463,"createdAt":464,"updatedAt":465,"publishedAt":466,"locale":10,"title":467,"introduction":468,"content":469,"slug":470},{"id":767,"documentId":768,"createdAt":769,"updatedAt":770,"publishedAt":771,"locale":10,"title":772,"introduction":773,"content":774,"slug":775},431,"it056tjampj9j84may9sx026","2026-01-13T15:51:46.463Z","2026-01-26T08:31:37.920Z","2026-01-26T08:31:38.217Z","Cleanroom Manufacturing of Thermoformed Plastic Parts – High Hygiene Standards","Cleanroom manufacturing of thermoformed plastic parts plays a crucial role in industries where stringent sterility requirements are essential. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What is Cleanroom Manufacturing?\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Arbeiten_im_Reinraum_2a8a3215c7.jpg\" alt=\"Arbeiten im Reinraum\">\u003Cfigcaption>Working in a cleanroom\u003C/figcaption>\u003C/figure>\u003Cp>Cleanroom manufacturing, also known as controlled environment production or cleanroom technology, enables the production of high-quality, customized components used in sensitive industries such as medical technology, electronics, and aerospace.\u003C/p>\u003Cp>The primary goal of cleanroom manufacturing is to prevent contamination of products by airborne particles. A cleanroom is a highly controlled environment designed to maintain an extremely low concentration of airborne contaminants that are often invisible to the naked eye.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is a Cleanroom?\u003C/span>\u003C/h3>\u003Cp>A cleanroom is a specially designed space that is continuously monitored and regulated to ensure the highest level of purity and precision in production. Cleanroom manufacturing follows strict standards for air quality, particle concentration, and environmental conditions.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What are the Requirements for a Cleanroom?\u003C/span>\u003C/h3>\u003Cp>A critical aspect of cleanroom manufacturing for thermoformed plastic parts is the use of specialized materials. These materials must meet the stringent requirements of the thermoforming process while also complying with cleanroom purity standards. Some requirements include:\u003C/p>\u003Cul>\u003Cli>The use of low-particle-emission plastics\u003C/li>\u003Cli>Special coatings or treatments to minimize contamination\u003C/li>\u003Cli>Strict adherence to hygiene protocols\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">The Thermoforming Process in Cleanroom Manufacturing \u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Schutzvorkehrungen_fuer_die_Reinraumfertigung_1c833cca1e.jpg\" alt=\"Schutzvorkehrungen bei der Reinraumfertigung\">\u003Cfigcaption>Precautions for cleanroom manufacturing\u003C/figcaption>\u003C/figure>\u003Cp>Thermoforming is a process in which plastic sheets or films are heated and shaped into three-dimensional forms. In a cleanroom environment, this process is conducted under controlled conditions to prevent contamination of the final plastic components.\u003C/p>\u003Cp>This is particularly critical for products such as medical implants, electronic components, and aerospace parts, where even minor contamination could have serious consequences.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is Allowed in a Cleanroom?\u003C/span>\u003C/h3>\u003Cp>Only personnel, materials, and equipment that meet the defined cleanliness standards are permitted in a cleanroom. Working in a cleanroom requires specialized clothing, tools, and filtration systems to maintain sterility.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Why Manufacture Thermoformed Plastic Parts in a Cleanroom?\u003C/span>\u003C/h3>\u003Cp>Reliable functional safety is important in sensitive areas such as medicine and pharmaceuticals, electronics, and food. Specific plastic products are manufactured in cleanroom production to prevent airborne dirt particles from interfering with the production of supplier parts.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of plastic thermoformed parts manufactured in cleanroom production\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Optimal cleanliness:\u003C/strong> The controlled cleanroom environment ensures that the cleanroom products manufactured are free of contamination.\u003C/li>\u003Cli>\u003Cstrong>Versatile applications:\u003C/strong> Thermoformed parts manufactured in cleanroom production are used in sensitive areas such as medicine, electronics, and aerospace.\u003C/li>\u003Cli>\u003Cstrong>Improved reliability:\u003C/strong> The elimination of contamination in the cleanroom increases the reliability and performance of the thermoformed parts.\u003C/li>\u003C/ul>\u003Cp>Regardless of cleanroom production, the manufacture of plastic parts using the thermoforming process enables exceptional precision and tight tolerances. Thermoformed parts are therefore ideal for demanding applications that require complex geometries.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production is essential for these end markets in plastic thermoformed parts.\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Semiconductor manufacturing\u003C/li>\u003Cli>Optical and laser technology\u003C/li>\u003Cli>Aerospace\u003C/li>\u003Cli>Life sciences\u003C/li>\u003Cli>Medical treatment and research\u003C/li>\u003Cli>Manufacture of sterile implants, wound dressings, thermoformed trays, and other medical assemblies\u003C/li>\u003Cli>Germ-free production of pharmaceuticals and food\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production for the automotive industry\u003C/span>\u003C/h2>\u003Cp>Cleanroom production is also becoming increasingly important for the automotive industry. It enables automotive manufacturers and suppliers to ensure that parts and components are manufactured to the highest cleanliness standards. Cleanliness requirements are particularly critical in sensitive vehicle parts such as ABS or direct injection systems. These components are extremely sensitive to contamination, especially particle residues.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Automobilbranche_e8fbcb51d9.jpg\" alt=\"VDA 19 - Technische Sauberkeit in der Automobilindustrie\">\u003Cfigcaption>VDA 19 - Technical cleanliness in the automotive industry\u003C/figcaption>\u003C/figure>\u003Cp>\u003Cstrong>VDA 19\u003C/strong>, or more precisely VDA 19.1, is a guideline developed specifically for the automotive industry to ensure the technical cleanliness of functionally relevant automotive parts. This guideline was created to meet the need for industry-wide standards and test methods.\u003C/p>\u003Cp>By defining specifications for clean production and testing methods, VDA 19.1 creates a basis for assessing the technical cleanliness of components in various phases of the production process. These include initial sampling, outgoing/incoming inspection, quality control of cleanliness-relevant manufacturing processes, and monitoring of process steps.\u003C/p>\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>ℹ️ \u003Cb>E-mobility:\u003C/b> Cleanroom manufacturing plays a crucial role in the context of e-mobility in the automotive industry. The use of cleanroom technologies ensures a clean and precise manufacturing environment that meets the high demands of assembling batteries, power electronics, and other key components. \u003C/p>\n\u003C/div>\u003C/div>\u003Cp>The combination of cleanroom manufacturing and VDA 19 thus creates a basis for the production of high-quality and technically clean components in the automotive industry.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Most important cleanroom classes according to various standards\u003C/span>\u003C/h2>\u003Cul>\u003Cli>For semiconductor technology \u003Cstrong>ISO 14644-1\u003C/strong> and \u003Cstrong>2\u003C/strong>\u003C/li>\u003Cli>For aerospace technology also \u003Cstrong>ISO 14644\u003C/strong>\u003C/li>\u003Cli>In food technology according to standard \u003Cstrong>VDI 2083\u003C/strong>\u003C/li>\u003Cli>In the pharmaceuticals guideline \u003Cstrong>EU-GMP\u003C/strong> with \u003Cstrong>Annex 1\u003C/strong>\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">Classes in cleanroom manufacturing\u003C/span>\u003C/h3>\u003Cp>The cleanroom classes with all their conditions are listed here again with all the most important cleanroom guidelines:\u003C/p>\u003Ch4>Purity classes according to ISO 14644-1\u003C/h4>\u003Cul>\u003Cli>Cleanroom classified according to ISO 1-9\u003C/li>\u003Cli>Cleanroom classes may only contain a particle count between 0.1 µm and 5 µm\u003C/li>\u003C/ul>\u003Ch4>Cleanliness classes according to EU-GMP guideline Annex 1\u003C/h4>\u003Cul>\u003Cli>GMP guideline defines cleanroom classes according to A, B, C, and D\u003C/li>\u003Cli>Here, only the maximum permitted particles per cubic meter are differentiated according to sizes greater than or equal to 0.5 µm and greater than or equal to 5 µm\u003C/li>\u003C/ul>\u003Ch4>VDI Guideline 2083 – Definition and function of a cleanroom\u003C/h4>\u003Cul>\u003Cli>Defines how a cleanroom is defined, how it works, and what needs to be considered\u003C/li>\u003Cli>The guideline deals exclusively with permissible concentrations of particles in the air at the so-called clean workplace\u003C/li>\u003Cli>As with DIN EN ISO 14644, only particles in the size range between 0.1 µm and 5 µm are considered\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">How can formary guarantee sterile conditions for cleanroom production?\u003C/span>\u003C/h2>\u003Cp>formary has access to a network of partners that enables cleanroom production and additional hygiene levels, allowing us to meet all hygiene standards for thermoformed parts. Use the configurator to request your individual thermoformed part under cleanroom conditions now.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Cleanroom production for plastic thermoformed parts – a summary\u003C/span>\u003C/h2>\u003Cp>Cleanroom production of plastic thermoformed parts plays a key role in industries that require the highest quality standards and purity requirements. Working in a cleanroom not only ensures the production of hygienic and clean parts, but also helps to improve the reliability and performance of products in sensitive applications.\u003C/p>\u003Cp>Through its specialized supply network, formary ensures that the right manufacturers design and produce thermoformed parts for every industry that requires high hygiene standards.\u003C/p>\u003Cp>\u003Cstrong>Do you have any further questions? Feel free to give us a call at \u003C/strong>\u003Cspan style=\"color:#005250;\">\u003Cstrong>+49 7191 9525170!\u003C/strong>\u003C/span>\u003C/p>\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 Thermoformed blisters in medical technology also benefit from high hygiene standards. Find out more here in our\n \u003Ca href=\"https://www.formary.de/en/whitepaper-ebooks/relevance-of-thermoformed-blisters-in-medical-technology\"> Whitepaper \u003C/a> On the relevance of medicine blister packs in medical technology.\n\u003C/p>\n    \u003C/div>\u003C/div>","cleanroom-manufacturing-of-themoformed-parts",{"id":777,"documentId":778,"createdAt":779,"updatedAt":780,"publishedAt":781,"locale":10,"title":782,"introduction":783,"content":784,"slug":785},447,"pocmz2z9l3ht47z25g69f626","2026-01-13T15:51:49.526Z","2026-01-26T08:39:48.215Z","2026-01-26T08:39:48.570Z","Thermoforming vs 3D Printing – Advantages, Disadvantages, Differences, and Similarities","Plastic parts are manufactured using various processing methods. In this article, we focus on comparing the processes of plastic thermoforming and 3D printing.","\u003Cp>Both 3D printing and thermoforming have different applications, advantages, and challenges. In this blog post, we take a closer look at these two plastic processing technologies to help you decide which is best for your use case.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does Thermoforming Work?\u003C/span>\u003C/h2>\u003Cp>Thermoforming, also known as plastic deep drawing, involves heating thermoplastic sheets and shaping them using vacuum or pressure in deep-drawing machines. Once cooled, the material is cut into the desired shape through punching or milling. One key advantage of thermoforming is the ability to produce large parts in various forms.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Cstyle>.c-container {border: 2px solid #15A9A4;padding: 10px;margin: 10px;border-radius: 10px;}.c-container {margin: 0;}\u003C/style>\u003Cdiv class=\"c-container\"> \u003Cp> ℹ️ In addition to classic plastic thermoforming, also known as the single-sheet process, there is also twin-sheet thermoforming, in which two plastic films/sheets are heated simultaneously. For more information, see our blog post on the \u003Ca href=\"https://www.formary.de/en/blog/twin-sheet-process\">twin-sheet process.\u003C/a> \u003C/p>\u003C/div>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">The Thermoforming Process\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:24.78%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehprozess_276e918f0c.png\" alt=\"Kunststoffumformen auf einem Negativ-Werkzeug\">\u003Cfigcaption>\u003Cspan style=\"background-color:rgb(247,247,247);color:rgb(51,51,51);\">Thermoforming on a negative mold\u003C/span>\u003C/figcaption>\u003C/figure>\u003Cp>The thermoforming process follows these steps:\u003C/p>\u003Col>\u003Cli>\u003Cstrong>Heating\u003C/strong>: The thermoplastic is heated to the forming temperature, making it soft and elastic.\u003C/li>\u003Cli>\u003Cstrong>Forming\u003C/strong>: The plastic sheet is stretched into the desired shape by positioning it over a mold and applying vacuum or pressure. This process typically takes only a few seconds.\u003C/li>\u003Cli>\u003Cstrong>Cooling\u003C/strong>: Once shaped, the plastic cools and solidifies, with the cooling process aided by contact with an aluminum mold.\u003C/li>\u003Cli>\u003Cstrong>Trimming\u003C/strong>: The formed part is separated from excess material using punching or milling techniques.\u003C/li>\u003C/ol>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is 3D Printing?\u003C/span>\u003C/h2>\u003Cp>3D printing, also known as additive manufacturing (AM), starts with creating a digital 3D model, which is then sliced into thin horizontal layers. The 3D printer builds the object layer by layer by depositing material, typically plastic.\u003C/p>\u003Cp>Invented in the early 1980s, 3D printing was initially slow and expensive. However, with significant technological advancements, it has become a widely used manufacturing method across various industries.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Different Types of 3D Printing?\u003C/span>\u003C/h2>\u003Cp>There are several types of 3D printing processes. The three most common are:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>SLS (Selective Laser Sintering)\u003C/strong>: A laser fuses plastic powder particles to build a 3D part layer by layer. The unused powder can be reused, making this process material-efficient.\u003C/li>\u003Cli>\u003Cstrong>SLA (Stereolithography)\u003C/strong>: A laser cures liquid resin to form the desired shape. This method offers high precision but has limited material options.\u003C/li>\u003Cli>\u003Cstrong>FDM (Fused Deposition Modeling)\u003C/strong>: A plastic filament is melted and extruded layer by layer to form the object. After printing, support structures may need to be removed.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">\u003Cstrong>How Does 3D Printing Work?\u003C/strong>\u003C/span>\u003C/h2>\u003Cp>Here is a simplified breakdown of the FDM 3D printing process:\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.13%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/schritt1_4164e21477.png\" alt=\"3D Druck - Vorbereitung Druckbett \">\u003Cfigcaption>3D printing material preparation\u003C/figcaption>\u003C/figure>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.41%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/schritt2_678986dfc9.png\" alt=\"3D-Druck Material Aufheizen \">\u003Cfigcaption>Heating up the 3D printer\u003C/figcaption>\u003C/figure>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.19%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/schritt3_802f958beb.png\" alt=\"3D Druck auftragen der Schichten\">\u003Cfigcaption>Applying the layers\u003C/figcaption>\u003C/figure>\u003Cp> \u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:20.18%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/4_d0fbc2e860.png\" alt=\"3D Druck Auskühlen und härten\">\u003Cfigcaption>Cooling and hardening\u003C/figcaption>\u003C/figure>\u003Col>\u003Cli>\u003Cstrong>Material Preparation\u003C/strong>: The 3D printer is loaded with filament, and print settings such as temperature and speed are configured. The print bed is also prepared for proper adhesion.\u003C/li>\u003Cli>\u003Cstrong>Heating\u003C/strong>: The 3D printer heats the material to a molten state.\u003C/li>\u003Cli>\u003Cstrong>Layer Deposition\u003C/strong>: The printer deposits material layer by layer to build the object.\u003C/li>\u003Cli>\u003Cstrong>Cooling & Hardening\u003C/strong>: The finished part cools and solidifies. Post-processing, such as removing supports or smoothing surfaces, may be required.\u003C/li>\u003C/ol>\u003Ch2>\u003Cspan style=\"color:#005250;\">Key Differences Between Thermoforming and 3D Printing\u003C/span>\u003C/h2>\u003Cp>The most striking differences between thermoforming and 3D printing are highlighted in this comparison of the two processes.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:15.46%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/1_4c9502efc1.png\" alt=\"Tabelle Unterschied Thermoformen und 3D-Druck\">\u003Cfigcaption>Thermoforming versus 3D printing: a direct comparison\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Quantities in 3D printing and deep drawing\u003C/span>\u003C/h3>\u003Cp>The usual quantities for 3D printing are in the prototype range, which is significantly lower than for thermoforming. 3D printing does not require any tools for the production of plastic parts. The production of 3D-printed parts therefore requires no lead times if the material is in stock, and delivery times of just a few days are possible.\u003C/p>\u003Cp>This makes the process particularly popular for sampling and \u003Cspan style=\"color:#005250;\">\u003Cstrong>prototyping\u003C/strong>\u003C/span>. However, the application of 3D printing for larger series production is limited by factors such as slower production speeds, poor scalability, and higher material costs.\u003C/p>\u003Cp>In comparison, deep-drawn parts can be produced at high cycle speeds and production can be scaled using appropriate tool designs. The thermoforming process can therefore be flexibly adapted to quantities ranging from 5 pieces to millions. This requires the tool mentioned above, which will be discussed in the next section.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D printing and thermoforming tool costs\u003C/span>\u003C/h3>\u003Cp>Depending on the design, material, number of uses, size, and structure, thermoforming tools cost between €500 and €10,000, but can be significantly higher for large parts or multi-use tools. With 3D printing, the costs are normally €0, as \u003Cstrong>no tools\u003C/strong> are required.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Production time for deep-drawing tools\u003C/span>\u003C/h3>\u003Cp>Additive processes such as 3D printing technology can produce the finished parts virtually overnight once the design has been created and approved. This is not possible with thermoforming in this form.\u003C/p>\u003Cp>However, in the best case scenario, thermoforming tools can be milled by the toolmaker in just 1-2 weeks. Normally, several weeks are required for production up to sampling. This has a significant impact on the delivery times for initial series in deep drawing.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Tolerances in deep drawing and 3D printing\u003C/span>\u003C/h3>\u003Cp>Deep-drawn components are designed with a tolerance of approximately +/- 1 mm in most industrial and packaging applications. This tolerance corresponds to the range specified in ISO 2768-c for the common length dimension of 120 to 400 mm in this product segment.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:7.3%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/lg_cover_design_guide_3a6b8e006b_4ee535bcfd.png\" alt=\"Tiefzieh Guide \">\u003Cfigcaption>Thermoform Guide\u003C/figcaption>\u003C/figure>\u003Cp>In 3D printing, tolerances vary depending on the printing process, ranging from ±0.2% for SLA to ±0.5% for FDM.\u003C/p>\u003Cp>More information about thermoforming quantities, delivery times, and more can be found in the \u003Cspan style=\"color:#005250;\">\u003Cstrong>Design Guide\u003C/strong>\u003C/span>. If you want to know how other plastic processing methods differ from plastic thermoforming, read our blog post “\u003Cspan style=\"color:#005250;\">\u003Cstrong>Injection Molding vs. Thermoforming\u003C/strong>\u003C/span>.”\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Possibilities and limitations of thermoforming\u003C/span>\u003C/h2>\u003Cp>Thermoforming is proving to be an extremely cost-effective option, even for large quantities. This is due to a number of advantages of plastic deep drawing, including fast and inexpensive production, low tooling costs compared to processes such as injection molding, and high material efficiency.\u003C/p>\u003Cp>Further advantages include flexibility in mold design and the ability to reproduce complex geometries with precision. The wide range of materials, additives, and surface finishes available for semi-finished products also make thermoforming an extremely attractive solution in various industries.\u003C/p>\u003Cp>The disadvantage, depending on the production run size, is the necessary investment in a mold.\u003C/p>\u003Ch4>Overview of the advantages and disadvantages of thermoforming\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of thermoforming Disadvantages of thermoforming\u003C/span>\u003Cbr> \u003C/th>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of thermoforming\u003C/span>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Low investment costs for tools\u003C/td>\u003Ctd>Tool adjustments can be expensive\u003Cbr> \u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Cost-effective production\u003C/td>\u003Ctd>Potential sources of error in semi-finished product manufacturing due to frozen stresses in the material during extrusion\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Worthwhile even for small quantities\u003C/td>\u003Ctd>Complex shapes with very thin walls are limited\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Optimal options for post-processing\u003C/td>\u003Ctd>Potential difficulty in achieving uniform material thicknesses in complex shapes\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Post-industrial recycling possible for simple cycles \u003C/td>\u003Ctd>One-sided material contact\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Unrivaled for thin-walled parts\u003C/td>\u003Ctd>More complex geometries cannot be produced using 3D printing\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Short lead times\u003C/td>\u003Ctd>Semi-finished products more expensive than with 3D printing\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Large selection of materials \u003C/td>\u003Ctd>Cutting and punching costs\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>All sizes and shapes possible (large parts)\u003C/td>\u003Ctd>Complex geometries that cannot be produced using 3D printing\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the advantages and disadvantages of 3D printing?\u003C/span>\u003C/h2>\u003Cp>3D printing offers several advantages, but also has some limitations compared to thermoforming.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages of 3D printing\u003C/span>\u003C/h3>\u003Cp>3D printing enables the production of complex, customized parts with high precision and minimal material waste. This leads to material and cost savings for smaller quantities or prototype development. In addition, there is no need for costly molds or tools for production, which reduces the initial investment.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D printing disadvantages\u003C/span>\u003C/h3>\u003Cp>3D printing is generally slower and less cost-efficient\u003Cstrong> \u003C/strong>for large production runs. The limited choice of materials and their strength may also mean that 3D printing is not suitable for all applications. In addition, the layered structure of the parts may require time-consuming post-processing, which takes up time and resources.\u003C/p>\u003Cp>In comparison, a deep-drawn part can often be used without additional grinding, polishing, or painting. The desired finish can be achieved directly with the material or by incorporating an impression of the desired surface structure into the tool.\u003C/p>\u003Ch4>Overview of the advantages and disadvantages of 3D printing\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Advantages of 3D Printing\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Disadvantages of 3D Printing\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>No tooling costs\u003C/td>\u003Ctd>Low quantities\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Short delivery times\u003C/td>\u003Ctd>Slow manufacturing process\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Complex shapes possible\u003C/td>\u003Ctd>Limited material selection\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>No long setup times & tool changes\u003C/td>\u003Ctd>Surface may require post-processing\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>No tool adjustments\u003C/td>\u003Ctd>Component size limited\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Constant price per part\u003C/td>\u003Ctd>Manufacturing process is more prone to errors, especially with complex components\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Shortened production time for prototypes\u003C/td>\u003Ctd>Slightly larger manufacturing tolerances\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>/\u003C/td>\u003Ctd>Low material efficiency → necessary support structures\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">3D printing possibilities and areas of application\u003C/span>\u003C/h2>\u003Cp>The 3D printing process offers a wide range of applications, from prototype development to the manufacture of customized medical implants. 3D printing not only enables cost-efficient solutions, but also contributes to improving patient care and the economical production of small series.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Samples/small series and prototypes\u003C/span>\u003C/h3>\u003Cp>3D printing is particularly suitable for the cost-effective production of small series, as no expensive tools are required. This is particularly advantageous for companies that require flexible and demand-driven production of construction or replacement parts. In addition, 3D printing technology is ideal for producing detailed samples and models, especially in industries such as design and architecture, where realistic models are essential for planning and visualization.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Healthcare\u003C/span>\u003C/h3>\u003Cp>In healthcare, 3D printing enables the production of customized medical components that can be tailored precisely to the individual characteristics of a patient. This increases the chances of successful implantation and minimizes the risk of complications.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industry\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:12.17%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Industrie_5f7892bbdb.jpg\" alt=\"Industrie\">\u003C/figure>\u003Cp>3D printing is used in various industries, such as mechanical engineering and automotive, to manufacture customized spare parts. This enables efficient production of components, especially for models where conventional manufacturing methods may no longer be economical.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Deep drawing Application areas\u003C/span>\u003C/h2>\u003Cp>The deep drawing process opens up a wide range of applications, from transport packaging and automation trays to housings and covers to blister packaging.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive\u003C/span>\u003C/h3>\u003Cp>In the automotive industry, deep drawing has established itself as the preferred method for manufacturing automation trays and transport trays. Choosing the right transport system is crucial for the safe transport of car body parts, electronic components, and other vehicle components.\u003C/p>\u003Cp>Thanks to the high formability of plastics, deep drawing enables the production of complex and efficient component carriers that optimally support your manufacturing process. These carrier systems not only ensure safe transport, but also help to support the efficiency of the entire manufacturing process.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Industry & mechanical engineering\u003C/span>\u003C/h3>\u003Cp>Deep drawing enables cost-effective production in \u003Cspan style=\"color:#005250;\">\u003Cstrong>industry\u003C/strong>\u003C/span> and \u003Cspan style=\"color:#005250;\">\u003Cstrong>mechanical engineering\u003C/strong>\u003C/span>\u003Cstrong> \u003C/strong>of\u003C/p>\u003Cul>\u003Cli>Housings\u003C/li>\u003Cli>Covers\u003C/li>\u003Cli>Screen frames\u003C/li>\u003Cli>and machine parts\u003C/li>\u003C/ul>\u003Cp>which are installed in machines. Automation and workpiece carriers are used in machines, automated production lines, and industrial robots. In production, deep-drawn plastic parts are mainly used as workpiece trays, which enable simple and optimized handling along the production or assembly line.\u003C/p>\u003Cp>Deep-drawn plastic trays and deep-drawn containers are used for chemicals and liquids, as molding forms or covers. When cleaning dirty or oily components, plastic trays are used as workpiece carriers, which transport the components safely through professional washing lines.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Electrical industry\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:13.05%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Elektronikindustrie_3bea71f08d.jpg\" alt=\"Elektrionikindustrie\">\u003C/figure>\u003Cp>Deep-drawn parts with \u003Cstrong>ESD protection\u003C/strong> protect delicate electronic components from electrostatic charging and discharge. ESD protection parts can be used in \u003Cspan style=\"color:#005250;\">\u003Cstrong>transport and warehouse logistics\u003C/strong>\u003C/span> as well as in \u003Cspan style=\"color:#005250;\">\u003Cstrong>housings and trim parts\u003C/strong>\u003C/span>. ESD protection prevents charge exchange that could damage your components. This is achieved through specific surface resistance and the right choice of materials. You can find out which materials are suitable for this purpose \u003Cspan style=\"color:#005250;\">\u003Cstrong>here\u003C/strong>\u003C/span>\u003Ca href=\"https://www.formary.de/branchen/elektronik-halbleitertechnologie\">.\u003C/a>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Thermoforming and 3D printing – a conclusion\u003C/span>\u003C/h2>\u003Cp>In conclusion, the comparison of thermoforming and 3D printing shows that both technologies have specific strengths and weaknesses that should be considered depending on the requirements of a project or product.\u003C/p>\u003Cp>3D printing is particularly suitable for creating short-term prototypes and small quantities. Thermoforming is a \u003Cstrong>cost-effective\u003C/strong> option for medium to large quantities. In addition, thermoforming offers fast production costs, comparatively low tooling costs, and material efficiency, as well as broad material requirements.\u003C/p>\u003Cp>Do you have any questions about thermoforming? We are happy to help. Simply \u003Cspan style=\"color:#005250;\">\u003Cstrong>contact\u003C/strong>\u003C/span> us or subscribe to our \u003Cspan style=\"color:#005250;\">\u003Cstrong>newsletter\u003C/strong>\u003C/span> for the latest information from the world of thermoformed parts!\u003C/p>","thermoforming-vs-3d-printing",{"id":787,"documentId":788,"createdAt":789,"updatedAt":790,"publishedAt":791,"locale":10,"title":792,"introduction":793,"content":794,"slug":795},437,"m8zzptx9l09znjfx044u28ia","2026-01-13T15:51:47.618Z","2026-01-26T08:34:06.659Z","2026-01-26T08:34:07.412Z","Cleaning Trays: This is how to clean reusable trays","Workpiece carriers transport components in various stages of production and are used for long periods. Many components, especially in the automotive industry, are oily or greasy, and during transport, dirt and other contaminants accumulate. Therefore, it is important to clean the trays.","\u003Ch2>\u003Cspan style=\"color:#005250;\">How does tray cleaning affect design?\u003C/span>\u003C/h2>\u003Cp>The cleaning of used \u003Ca href=\"https://www.formary.de/en/solutions/trays-for-transportation-storage\">plastic trays\u003C/a> and \u003Ca href=\"https://www.formary.de/en/blog/what-is-a-workpiece-carrier\">workpiece carriers\u003C/a> usually takes place at the end of the production chain or is even completely separated from the production process and carried out by external service providers. Trays are usually designed with a focus on the production process they are intended to optimize. Nevertheless, it is important to consider tray cleaning right from the start of development. That's why you can specify washing processes in the \u003Ca href=\"https://www.formary.de/en/configurator\">configurator\u003C/a> when you make your inquiry.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How is a tray cleaned industrially?\u003C/span>\u003C/h2>\u003Cp>In most cases, production sites sort trays that need to be cleaned and place them at a collection point where they are picked up for workpiece carrier cleaning. The trays are then cleaned either in-house or by an external service provider. \u003Cstrong>Industrial washing systems\u003C/strong> are used for this purpose. The designs of the washing systems are as varied as the items, workpiece carriers, and components being cleaned. In simplified terms, the washing process usually involves the following steps:\u003C/p>\u003Cul>\u003Cli>Pre-sorting\u003C/li>\u003Cli>Removal of foreign objects (e.g., labels)\u003C/li>\u003Cli>Multi-stage washing process as required, e.g.:\u003Cul>\u003Cli>Pre-wash zone\u003C/li>\u003Cli>Ultrasonic\u003C/li>\u003Cli>Spraying\u003C/li>\u003Cli>Immersion degreasing\u003C/li>\u003Cli>Injection flood washing\u003C/li>\u003Cli>High-pressure water jet technology\u003C/li>\u003C/ul>\u003C/li>\u003Cli>Drying process\u003C/li>\u003C/ul>\u003Cp>The latter is particularly important for \u003Cstrong>delicate electronic components\u003C/strong>, where residual moisture can quickly lead to corrosion. After the professional cleaning process, the reusable workpiece carriers can be returned to the production cycle immediately.\u003C/p>\u003Cp>Plastic and trays are exposed to particular stresses during industrial cleaning. We will take a closer look at these in the next section.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What must the tray withstand during cleaning?\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Solvents\u003C/li>\u003Cli>Chemicals\u003C/li>\u003Cli>Mechanical high-pressure water\u003C/li>\u003Cli>High temperatures\u003C/li>\u003C/ul>\u003Cp>Effects on the tray during the washing process\u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:22.52%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_f5063a52fa.png\" alt=\"Einwirkungen auf das Tray beim Waschprozess\">\u003Cfigcaption>Effects on the tray during the washing process\u003C/figcaption>\u003C/figure>\u003Cp>What workpiece carriers have to endure during the washing process naturally depends on the degree of contamination, the type of dirt, and the required hygiene standard. Solvents are used to remove grease, oil, or paint. Chemicals that remove residues can also have an aggressive effect on the surface of the tray. Mechanical high-pressure water can affect delicate contours, and drying processes expose the tray to high temperatures.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Cleaning trays: Cleaning techniques\u003C/span>\u003C/h3>\u003Cp>The \u003Cstrong>ultrasonic washing system\u003C/strong> is a gentle method for cleaning workpiece carriers. Even containers with the most stubborn residues can be cleaned without the use of aggressive cleaning chemicals. During ultrasonic cleaning, the workpiece carrier is placed in a bath that is set into vibration by sound waves. This creates positive and negative pressure in the cavities of the liquid, generating tiny bubbles. When the bubbles burst, this movement pulls the dirt off the surface.\u003C/p>\u003Cp>Drying can be carried out using \u003Cstrong>vacuum technology\u003C/strong>. Drying processes for sensitive components are carried out using warm air circulation systems or contactless, antistatic air cleaners. The possibilities are endless.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How your tray survives many washing processes unscathed\u003C/span>\u003C/h2>\u003Cp>Since we have already designed many thermoformed trays and workpiece carriers that are suitable for industrial cleaning systems, we can tell you what is important.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1.) The right choice of material\u003C/span>\u003C/h3>\u003Cp>Reusable containers are generally made from thicker materials to ensure that the tray remains stable for months or years of use. In addition, properties such as\u003C/p>\u003Cul>\u003Cli>impact strength\u003C/li>\u003Cli>hardness\u003C/li>\u003Cli>and resistance\u003C/li>\u003C/ul>\u003Cp>to various substances. What will the tray come into contact with and what solvents will be used to clean it? Only plastics that are non-reactive with the relevant substances and are resistant to them are selected.\u003C/p>\u003Cp>Although using high-quality plastic and thicker material is more expensive initially, the investment quickly pays for itself. A high-quality tray needs to be replaced less often and retains its stability and quality. Reusable trays therefore make sense not only from an environmental point of view, but also for economic reasons.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">2.) Observe design must-dos with regard to tray cleaning\u003C/span>\u003C/h3>\u003Cp>The design of the tray depends on the \u003Cstrong>environmental influences\u003C/strong> it has to withstand – including during workpiece carrier cleaning. Trays can be reinforced where high mechanical and dynamic stresses occur, and thin spots in cavities must be avoided. More complex tool designs support a long service life.\u003C/p>\u003Cp>Special features and post-processing support the cleaning of the tray. Plastic trays can be equipped with water-repellent edges. Holes can be milled into the bottom of the cavities or mold cavities so that water can drain off easily.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3.) Involve cleaning service providers\u003C/span>\u003C/h3>\u003Cp>The design is most efficient when the internal or external cleaning service provider is involved from the outset. To avoid unwanted chemical reactions, there are two approaches:\u003C/p>\u003Ch4>Cleaning agent used\u003C/h4>\u003Cp>Ask your service provider to specify the cleaning agent they plan to use. formary checks the data sheet for \u003Cstrong>compatibility\u003C/strong> with the plastic used.\u003C/p>\u003Ch4>Plastic used\u003C/h4>\u003Cp>formary will provide the service provider with a \u003Cstrong>cleaning agent recommendation\u003C/strong> for the plastic used. The service provider will check the compatibility of the cleaning agent with their equipment. If you develop your tray with us, formary will be happy to handle the communication. We know that it is worthwhile for your project to draw on the combined experience of plastics and cleaning experts.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Tray cleaning – ask the right questions and get the perfect product quickly\u003C/span>\u003C/h2>\u003Cp>Design your workpiece carrier for production with subsequent workpiece carrier cleaning now. You can find this configuration in the formary configurator under “Fine tuning & handling” and “Washability.” Learn more about the design of deep-drawn parts in our blog post \u003Ca href=\"https://www.formary.de/en/blog/construction-data-in-thermoforming\">\u003Cstrong>\u003Cu>“Release of design data”\u003C/u>\u003C/strong>\u003C/a> or in our \u003Ca href=\"https://www.formary.de/en/design-guide\">\u003Cstrong>\u003Cu>design guide\u003C/u>\u003C/strong>\u003C/a>.\u003C/p>\u003Cp>Configuration of the washing process in the formary product configurator\u003C/p>\u003Cp>\u003Cstrong>If you have any questions or feedback, please write to us now in LiveChat or call us at: +49 7191 9525170\u003C/strong>\u003C/p>","how-to-clean-trays",{"id":797,"documentId":798,"createdAt":799,"updatedAt":800,"publishedAt":801,"locale":10,"title":802,"introduction":803,"content":804,"slug":805},444,"p7sxm92yi6m2pzgb2lfq57xu","2026-01-13T15:51:49.000Z","2026-01-26T08:37:13.559Z","2026-01-26T08:37:13.593Z","Twin-Sheet Process: Definition, Advantages, and Applications","The Twin-Sheet process is a thermoforming technique that differs from the Single-Sheet process. In this method, two plastic sheets are heated and shaped simultaneously, enabling the production of hollow and stable components with complex geometries.","\u003Cp>In this article, we look at how the twin-sheet process works, its advantages, and its diverse applications in various industries.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the twin-sheet process?\u003C/span>\u003C/h2>\u003Cp>The twin-sheet process, also known as twin-sheet thermoforming, is a further development of \u003Ca href=\"https://www.formary.de/tiefziehen-kunststoff\">\u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic deep drawing\u003C/strong>\u003C/span>,\u003C/a> which is also known as the \u003Cstrong>single- or mono-sheet process\u003C/strong>. While conventional thermoforming involves forming a single \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic sheet\u003C/strong>\u003C/span> or \u003Cspan style=\"color:#005250;\">\u003Cstrong>roll\u003C/strong>\u003C/span>, the twin-sheet process involves processing two plastic sheets simultaneously to produce a hollow component.\u003C/p>\u003Cp>There are differences between the European and American versions: in the European version, the sheets are formed simultaneously, while in the American version they are formed one after the other.\u003C/p>\u003Cp>A crucial process step in twin-sheet technology is \u003Cstrong>negative thermoforming,\u003C/strong> in which both \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic films\u003C/strong>\u003C/span> are heated simultaneously to the thermoplastic range and then formed into a profiled component and welded together in a single operation.\u003C/p>\u003Cp>The high-strength bond between the sheets is created solely by the forming temperature and pressure, resulting in a particularly stable, stress-free bond. Twin-sheet thermoforming thus offers high strength and flexible design options.\u003C/p>\u003Cp>\u003Ci>ℹ️\u003C/i> \u003Ci>You can find out more about the differences between single-sheet thermoforming and twin-sheet thermoforming in this video:\u003C/i>\u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Ciframe width=\"560\" height=\"315\" src=\"https://www.youtube.com/embed/2_KRmNsF1Gw?si=wF4k0y1oAsk0lU1U\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen=\"\">\u003C/iframe>\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">How does the twin-sheet process work?\u003C/span>\u003C/h2>\u003Cp>The twin-sheet process consists of several steps and can be divided into the following process:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Material selection\u003C/span>\u003C/h3>\u003Cp>Two plastic sheets are clamped into the thermoforming machine. The sheets can be made of identical or different \u003Cspan style=\"color:#005250;\">\u003Cstrong>materials\u003C/strong>\u003C/span>, depending on the desired properties of the end product, such as strength, UV resistance, or \u003Cspan style=\"color:#005250;\">\u003Cstrong>ESD protection\u003C/strong>\u003C/span>\u003Ca href=\"https://www.formary.de/blog/esd-trays-aus-kunststoff-einsatz-und-vorteile\">.\u003C/a> This allows for a high degree of flexibility in the design of the thermoformed parts.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Heating\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:15.93%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Twin_Sheet_Verfahren_Schritt_1_0ed40429c1.png\" alt=\"Twin-Sheet-Verfahren: Erhitzung\">\u003Cfigcaption>Twin-sheet process: Heating\u003C/figcaption>\u003C/figure>\u003Cp>In the twin-sheet process, both plastic sheets are heated simultaneously until they reach the so-called thermoelastic state, in which they are soft and malleable. It is important that the heating is uniform in order to avoid material stresses and guarantee high-quality shaping. This step is typically carried out in special ovens that are integrated into the thermoforming machine.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Shaping\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.17%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Twin_Sheet_Verfahren_Formgebung_542af96377.png\" alt=\"Twin-Sheet-Verfahren: Formgebung\">\u003Cfigcaption>Twin-sheet process: shaping\u003C/figcaption>\u003C/figure>\u003Cp>Once the plastic rolls or sheets have reached the right temperature, they are placed in two separate halves of a mold. Each sheet is pressed into its own cavity, where it is drawn into the desired shape using \u003Cspan style=\"color:#005250;\">\u003Cstrong>vacuum\u003C/strong>\u003C/span> or \u003Cspan style=\"color:#005250;\">\u003Cstrong>compressed air\u003C/strong>\u003C/span>. This process enables precise shaping and ensures that even complex geometries can be reliably produced.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Welding\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:15.47%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Twin_Sheet_Verfahren_Verschweissung_9c69b46d92.png\" alt=\"Twin-Sheet-Verfahren Verschweißung\">\u003Cfigcaption>Twin-sheet process: Welding\u003C/figcaption>\u003C/figure>\u003Cp>While the sheets are still warm and malleable, the two mold halves are pressed together so that the plastic sheets fuse together at the points of contact. This results in a permanent and stable bond that forms a hollow structure. The double wall thickness creates a component with particularly high strength that meets the requirements for structural load-bearing capacity.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Cooling and removal of the component\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:16.17%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Twin_Sheet_Verfahren_Entnahme_a9426c60c8.png\" alt=\"Twin-Sheet-Verfahren: Abkühlung und Entnahme\">\u003Cfigcaption>Twin-sheet process: cooling and removal\u003C/figcaption>\u003C/figure>\u003Cp>Once the molded component has cooled, it is removed from the mold and can be used for further processing or direct use.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the advantages of the twin-sheet process?\u003C/span>\u003C/h2>\u003Cp>The twin-sheet process offers several significant advantages over other plastic processing methods:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Increased stability:\u003C/strong> Twin-sheet thermoforming is characterized by high structural strength, which is achieved by the double wall structure of the components. This not only ensures high stability, but also enables weight reduction, as stable and rigid parts can be produced with less material.\u003C/li>\u003Cli>\u003Cstrong>High accuracy\u003C/strong>: Both sides of the molded parts benefit from double-sided mold contact, which increases accuracy. This is reflected in the visually appealing quality of both sides of the component.\u003C/li>\u003Cli>\u003Cstrong>Cost-effectiveness\u003C/strong>: Compared to conventional processes such as blow molding or injection molding, the cost of the \u003Ca href=\"https://www.formary.de/blog/tiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">\u003Cspan style=\"color:#005250;\">deep-drawing tool\u003C/span>\u003C/a>\u003Cspan style=\"color:#005250;\"> \u003C/span>is often more cost-effective with the twin-sheet process. This is because two sheets are processed simultaneously, which reduces the need for additional processing steps and tools.\u003C/li>\u003Cli>\u003Cstrong>Large part dimensions\u003C/strong>: The process enables the production of very large parts at relatively low tool and part prices, which further increases cost-effectiveness.\u003C/li>\u003Cli>\u003Cstrong>Inserts and insert parts\u003C/strong>: The twin-sheet process allows inserts to be inserted directly into the cavity of the component. This means that complex shapes and integrated functional elements such as reinforcements or mounting points can be easily integrated into the component.\u003C/li>\u003Cli>\u003Cstrong>Material diversity\u003C/strong>: It is possible to combine different materials and colors on the inside and outside of the parts. A mix of new and \u003Cspan style=\"color:#005250;\">recycled \u003C/span>materials is also possible.\u003C/li>\u003Cli>\u003Cstrong>Fast implementation times\u003C/strong>: Even larger components can be produced quickly, which shortens production times.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">In which industries is the twin-sheet process used?\u003C/span>\u003C/h2>\u003Cp>The twin-sheet process is characterized by its versatility and is of great interest in numerous industries.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive\u003C/span>\u003C/h3>\u003Cp>In the \u003Cspan style=\"color:#005250;\">\u003Cstrong>automotive\u003C/strong>\u003C/span> sector, twin-sheet thermoforming is often used to manufacture air ducts, door panels, \u003Cspan style=\"color:#005250;\">\u003Cstrong>covers\u003C/strong>\u003C/span> for luggage compartments, and other interior trim. These applications benefit from the high strength and ability to efficiently produce complex geometries.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:53.3%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/lenny_kuhne_j_HZ_70n_Rk7_Ns_unsplash_69c025e3ea.jpg\" alt=\"Automotive-Branche\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Packaging\u003C/span>\u003C/h3>\u003Cp>Another important area is the packaging industry, where the twin-sheet process is used to produce stable and reusable \u003Cspan style=\"color:#005250;\">\u003Cstrong>thermoformed containers\u003C/strong>\u003C/span> and pallets.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Medical technology\u003C/span>\u003C/h3>\u003Cp>In \u003Cspan style=\"color:#005250;\">\u003Cstrong>medicine,\u003C/strong>\u003C/span> the process is used in the manufacture of \u003Cspan style=\"color:#005250;\">\u003Cstrong>medical technology housings\u003C/strong>\u003C/span>\u003Ca href=\"https://www.formary.de/produkte/medizintechnik-gehaeuse-aus-kunststoff\">,\u003C/a> which must be both lightweight and robust.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:69.81%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/national_cancer_institute_o_C_Lu_Fi9_GYNA_unsplash_0380e3eabd.jpg\" alt=\"Medizinbranche\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Consumer goods\u003C/span>\u003C/h3>\u003Cp>The process also plays a central role in the manufacture of \u003Cspan style=\"color:#005250;\">\u003Cstrong>consumer goods\u003C/strong>\u003C/span> such as leisure and sports equipment. For example, \u003Cspan style=\"color:#005250;\">\u003Cstrong>caravan covers,\u003C/strong>\u003C/span> kayaks, and other leisure equipment are produced using the twin-sheet process, enabling manufacturers to create high-performance yet lightweight products.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Twin-sheet thermoforming – a summary\u003C/span>\u003C/h2>\u003Cp>The twin-sheet process is a \u003Cstrong>powerful and flexible technology\u003C/strong> that offers numerous advantages in both mass production and special applications. Thanks to its ability to combine complex geometries with high structural strength and low weight, twin-sheet thermoforming is used in a wide range of industries.\u003C/p>\u003Cp>Would you like to know whether single-sheet thermoforming or the twin-sheet process is more suitable for your application? Then \u003Cspan style=\"color:#005250;\">\u003Cstrong>contact\u003C/strong>\u003C/span> us and we will be happy to help you.\u003C/p>","twin-sheet-process",{"id":807,"documentId":808,"createdAt":809,"updatedAt":810,"publishedAt":811,"locale":10,"title":812,"introduction":813,"content":814,"slug":815},426,"gn79sl32j0pu31hzm2ugo6lw","2026-01-13T15:51:45.558Z","2026-01-26T08:28:55.125Z","2026-01-26T08:28:55.829Z","Comparison: Plastic vs. Metal – Differences, Similarities, Advantages & Disadvantages","Metals and plastics are two essential material categories used across various industries and applications, from consumer goods manufacturing to the production of technical components.","\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In this article, we highlight the differences, similarities, advantages, and disadvantages of the two materials in these applications. \u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Structure and Composition of Plastic and Metal\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals have been a cornerstone of industrial development since the Industrial Revolution, finding widespread use in sectors such as automotive manufacturing, mechanical engineering, and energy production. Metals offer several advantages for enclosures, mechanical components, and technical parts, including:\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">High strength\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Heat resistance\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Aesthetic appeal\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals consist of metallic elements with a crystalline structure. This arrangement allows them to maintain high strength and toughness. The atoms in metals form a structured lattice, leading to high density and electrical conductivity.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Struktur_von_Werkstoffen_Vergleich_Kunststoff_und_Metall_f8fcfb5b28.jpg\" alt=\"Struktur von Werkstoffen Vergleich Kunststoff und Metall\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastics: Versatility and Lightweight Properties\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The development and use of plastics began in the 19th century, but their widespread adoption occurred in the 1950s. Plastics emerged as a cost-effective alternative to materials like metal, glass, and wood, becoming the preferred choice in industries such as construction, automotive, \u003C/span>\u003Ca href=\"https://www.formary.de/en/products/thermoformed-plastic-packaging\">\u003Cspan style=\"color:hsl(0,0%,0%);\">packaging\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">, and electronics. The key advantages of plastics include:\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">High moldability\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Lightweight properties\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Electrical insulation\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Corrosion resistance\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics are composed of long molecular chains known as polymers, which can have linear, branched, or cross-linked structures. When heated, these polymers become highly moldable and can be shaped into virtually any form. Once cooled, they solidify, gaining their structural integrity.\u003C/span>\u003C/p>\u003Cdiv class=\"raw-html-embed\">\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> \u003C/p>\u003Ch4>ℹ️ Why are plastics lighter than metals?\u003C/h4>\n    The lower density of polymers, which plastics are made of, means that they are generally lighter than metals.\n    \u003Cp>\u003C/p>\n\u003C/div>\n\u003C/div>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">There are \u003Cstrong>two main types\u003C/strong> of plastics:\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Thermosets\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">Thermoplastics\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Thermosets can only be moulded into a specific shape once, whereas thermoplastics can be moulded several times within certain limits. This property enables \u003C/span>\u003Ca href=\"https://www.formary.de/tiefziehen-kunststoff\">\u003Cspan style=\"color:hsl(0,0%,0%);\">plastic thermoforming,\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> in which \u003C/span>\u003Ca href=\"https://www.formary.de/plattenfertigung\">\u003Cspan style=\"color:hsl(0,0%,0%);\">plastic sheets\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> or \u003C/span>\u003Ca href=\"https://www.formary.de/rollenfertigung\">\u003Cspan style=\"color:hsl(0,0%,0%);\">rolls\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> are moulded into a different shape using pressure and heat.\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What properties does plastic have compared to metal?\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals and plastics have a range of properties that make them interesting for numerous applications.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Flexibility and mouldability - a benefit for plastics\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The mouldability of materials is important for many applications for several reasons. These include design flexibility in product design, manufacturability in mass production and the possibility of repairs and maintenance.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The properties mentioned above make plastics extremely flexible and mouldable in principle. They can be easily heated and formed into almost any desired shape using various processes such as thermoforming, blow moulding or injection moulding, which enables a wide variety of designs. Plastics are often more flexible and adaptable in terms of mouldability and require less energy-intensive processes.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals are generally formed by casting/injection moulding and brought into the desired shape by bending, pressing and edging, as well as machining (turning/milling), punching and welding. However, the moulding of metals can take more energy and time than with plastics. The interaction of these processes can be less flexible and more complex to mould a metal part into the desired shape. The complexity can increase manufacturing costs and limit design possibilities.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Strength and durability - a benefit for metal\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Components made from different materials should, in principle, be able to withstand the loads to which they are exposed and be as durable and efficient as possible.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Depending on the type, plastics offer good strength and durability. They can be manufactured to have certain mechanical properties, such as\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">impact resistance\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">rigidity\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">or flexibility.\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">However, plastics are generally more susceptible to scratches and wear and tear compared to metals.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals are known for their high strength, hardness and ductility. They can bear heavy loads without breaking and are therefore widely used in applications such as construction, the automotive industry and aerospace. Metals can withstand extreme temperatures of up to 500 degrees. This makes metals ideal for applications that require a robust and durable solution.\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages of plastics compared to metal\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">So what is the reason that plastic has replaced metal as a material in many applications in recent decades? In these aspects, plastics have numerous advantages over metals:\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:29.63%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tuerkise_Hand_ueber_der_sich_Pluszeichen_befinden_23477ff51e.jpg\" alt=\"Türkise Hand, über der sich Pluszeichen befinden\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Shock-absorbing properties\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In general, plastics have better shock absorption properties than metals, making them ideal for shock-absorbing applications such as \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/schutzabdeckung-aus-kunststoff-cnc-drehteile\">\u003Cspan style=\"color:hsl(0,0%,0%);\">protective covers\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">, bumpers, protective covers and packaging materials.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Noise insulation\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics have an improved noise-insulating effect compared to metals and can therefore effectively help to reduce noise in buildings, vehicles and machines, such as \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/kunststoffabdeckung-fuer-maschine-maschinenabdeckung\">\u003Cspan style=\"color:hsl(0,0%,0%);\">machine covers\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> and \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/traktor-abdeckungen-aus-kunststoff\">\u003Cspan style=\"color:hsl(0,0%,0%);\">tractor covers.\u003C/span>\u003C/a>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Chemical and corrosion resistance\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics are more resistant to many corrosive environments than metals. As a rule, they do not react with water, acids and alkalis, making them ideal for use in damp environments and chemical processes.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Electrical insulation capability\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics offer good electrical insulation properties. Examples of applications include \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/esd-werkstuecktraeger-fuer-elektronik\">\u003Cspan style=\"color:hsl(0,0%,0%);\">ESD workpiece carriers,\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/esd-transportverpackungen-aus-kunststoff\">\u003Cspan style=\"color:hsl(0,0%,0%);\">ESD transport packaging\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> and \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/kunststoffgehaeuse-fuer-elektronik-elektronikgehaeuse-kunststoff\">\u003Cspan style=\"color:hsl(0,0%,0%);\">electronic plastic housings\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">. In general, metals have a very low electrical insulation capacity compared to non-conductive materials such as plastic. Metals conduct electrical current, which is why they are not suitable as shielding in the form of enclosures.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Heat insulation capability\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics can be good thermal insulators, especially when compared to metals. The thermal conductivity of plastics is generally much lower than that of metals, which means that they conduct heat more slowly through their volume. This makes plastics effective thermal insulators in many applications, such as construction, the food/packaging industry, the electronics industry and the automotive industry.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Cost\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:31.33%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Hand_die_Geld_haelt_b436b97674.png\" alt=\"Hand, die Geld hält\">\u003C/figure>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics often have lower costs than metals, both in terms of material costs and manufacturing costs. Metals are produced by melting and moulding metal ores, followed by various processing methods such as casting, forging and rolling.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">These processes often require high temperatures, a corresponding amount of energy and special equipment, which increases the manufacturing costs in contrast to plastics. Plastics, on the other hand, can be produced in large quantities at comparatively favourable prices.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In terms of cost, the weight reduction of plastics is also an advantage, as less energy is required both during transport and storage and when used as a moving component in a machine. This leads to cost savings.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Environmental impact and recycling\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Although plastic and metal can be recycled, the recycling of metals requires the use of high temperatures and therefore\u003Cstrong> \u003C/strong>a very high energy input. In contrast, plastic can be shredded and reused as \u003C/span>\u003Ca href=\"https://www.formary.de/blog/was-ist-rezyklat-moeglichkeiten-im-kunststoff-recycling-und-abgrenzung-zu-neuware\">\u003Cspan style=\"color:hsl(0,0%,0%);\">recyclate\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffflakes_die_sich_in_den_Haenden_befinden_66b91b7e44.png\" alt=\"Kunststoffflakes, die sich in den Händen befinden\">\u003Cfigcaption>Recyclate\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Comparison of plastic vs. metal - an overview\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Properties of\u003C/span>\u003C/th>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">Metals\u003C/span>\u003C/th>\u003Cth>\u003Cspan style=\"color:hsl(0,0%,0%);\">plastics\u003C/span>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Structure\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Crystalline\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Polymer (linear, branched or cross-linked structure)\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Production costs\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Low\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Energy expenditure\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Low\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Design possibilities\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Medium\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Longevity\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Corrosion resistance\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Susceptible\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Resistant\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Strength\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Medium\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Stiffness\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Medium\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Ductility\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Variable\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">weight\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Heavy\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Light\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Electrical conductivity\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Conductive\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Electrical insulator\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Heat resistance\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Medium\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Thermal conductivity\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Low to medium\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Thermal insulation\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Low\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">High\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Manufacturing process\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Melting, casting, forging, rolling\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Polymerisation, injection moulding, extrusion, thermoforming\u003C/span>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Environmental impact\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Extraction and processing require energy and can cause environmental damage\u003C/span>\u003C/td>\u003Ctd>\u003Cspan style=\"color:hsl(0,0%,0%);\">Plastics can be further processed as recyclate, but are not biodegradable\u003C/span>\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Comparison of plastic vs. metal - a conclusion\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The choice between plastics and metals ultimately depends on the specific requirements of the application, including design requirements, functionality and cost. Both plastics and metals have specific strengths and weaknesses, and the right choice is made by carefully weighing up the various factors.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">For a more cost-effective production with the possibility of numerous design options, plastic is more suitable than metal. We will be happy to advise you! Get \u003C/span>\u003Ca href=\"https://www.formary.de/kontakt\">\u003Cspan style=\"color:hsl(0,0%,0%);\">in touch\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> with formary to clarify any questions you may have, for example on the use of \u003C/span>\u003Ca href=\"https://www.formary.de/blog/was-sind-biokunststoffe\">\u003Cspan style=\"color:hsl(0,0%,0%);\">bioplastics\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> in thermoforming.\u003C/span>\u003C/p>","plastics-vs-metal",{"id":817,"documentId":818,"createdAt":819,"updatedAt":820,"publishedAt":821,"locale":10,"title":822,"introduction":823,"content":824,"slug":825},433,"k15og2ckzlyxayxyfeyfle6w","2026-01-13T15:51:46.857Z","2026-01-26T08:32:21.547Z","2026-01-26T08:32:21.601Z","What is Pneumatic Forming? A Quick Guide to Shaping Plastic with Compressed Air","Pneumatic forming is a widely used technique for shaping thermoformed parts from rolls or sheets. This process utilizes compressed air to apply greater force during the forming stage, ensuring precise shaping and efficient production.\n\nFind out how pneumatic forming works and the key advantages it offers in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">How does compressed air moulding work?\u003C/span>\u003C/h2>\u003Cp>Compressed air moulding is used in the \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic thermoforming\u003C/strong>\u003C/span> and \u003Cspan style=\"color:#005250;\">\u003Cstrong>twin-sheet processes\u003C/strong>\u003C/span>. In compressed air moulding, the heated material is pressed precisely against the tool using \u003Cstrong>additional compressed air\u003C/strong>. Due to the more intensive forces involved, a robust tool design is important in order to withstand the pressure. In most cases, an aluminium tool is essential for air forming, as plastics, ureol or alternative pattern tool materials could collapse under the forming pressure or even damage the machine under certain circumstances. Vacuum moulding is an alternative.\u003C/p>\u003Cp>A \u003Cstrong>bottom-up approach\u003C/strong> is important for the optimum moulding pressure for hot forming with compressed air, starting with low pressure and gradually increasing it as required. The pressure should only be as high as necessary for the sharp shaping of the moulded part. An excessive increase in pressure leads to a waste of energy and also increases the risk of mould damage during production.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Druckluftformen_Der_Prozess_55fe192151.png\" alt=\"Druckluftform-Prozess\">\u003Cfigcaption>Compressed air moulding process\u003C/figcaption>\u003C/figure>\u003Cp>Compressed air moulding enables the use of specific moulding techniques for the targeted control of wall thickness distribution and geometries. For example, a bubble can be formed before the vacuum and \u003Cstrong>upper punch\u003C/strong> are applied in order to pre-stretch the heated material.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Druckluftformen_mit_Oberstempel_d8ce630535.png\" alt=\"Druckluftformen mit Oberstempel\">\u003Cfigcaption>Compressed air moulds with top punch\u003C/figcaption>\u003C/figure>\u003Cp>The \u003Cstrong>snapback process\u003C/strong>, which works with additional compressed air from the lower table, is another example.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Druckluftformen_mit_Snapback_Verfahren_a061ec9422.png\" alt=\"Druckluftformen mit Snapback-Verfahren\">\u003Cfigcaption>Compressed air moulds with snapback process\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and limitations of compressed air moulds\u003C/span>\u003C/h2>\u003Cp>Although compressed air machines are more cost-intensive, they offer several advantages due to their manufacturing method:\u003C/p>\u003Cul>\u003Cli>Shorter heating and cooling times enable shorter cycle times, which reduces the unit price.\u003C/li>\u003Cli>The lower forming temperature counteracts the risk of material sagging, supported by the higher forming pressure.\u003C/li>\u003Cli>Optimisation of moulding sharpness and material distribution, while at the same time preventing chill marks.\u003C/li>\u003C/ul>\u003Cp>Plastic forming with compressed air is particularly suitable for \u003Cstrong>higher quantities\u003C/strong>, where the investment in more expensive tools is quickly amortised. In addition to high quantities, compressed air moulding is also suitable for high mechanical and optical requirements, such as \u003Cstrong>clarity\u003C/strong> and \u003Cstrong>precise material distribution\u003C/strong> for technical plastics such as PC (polycarbonate). Even pre-printed parts can be moulded much better with compressed air than with vacuum forming.\u003C/p>\u003Cp>Find out more in our \u003Ca href=\"https://landing.formary.de/webinar/formary-illig-\">\u003Cstrong>formary x Illig webinar\u003C/strong>\u003C/a> on the topic of \"What is the right process for my thermoformed product?\"\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Compressed air moulding advantages and disadvantages\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of compressed air moulds\u003C/th>\u003Cth>Disadvantages of compressed air moulding\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Mould sharpness is sharper than with vacuum forming\u003C/td>\u003Ctd>Higher mould costs than with vacuum forming\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Lower risk of chill marks\u003C/td>\u003Ctd>Higher energy costs than with vacuum forming\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>High temperature resistance\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Shorter cycle times\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Suitable for large quantities\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp> \u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Compressed air moulds - A summary\u003C/span>\u003C/h2>\u003Cp>Compressed air moulding is an effective method for precise and economical thermoforming of plastics. The combination of targeted compressed air application and robust tools enables sharp moulding. Despite higher initial investments, compressed air machines offer an advantage over vacuum moulding machines thanks to shorter cycle times and higher temperature resistance.\u003C/p>\u003Cp>Compressed air moulding is particularly suitable for projects with high quantities and demanding requirements, such as technical plastics with clear view or pre-printed parts. Compressed air moulding is therefore a cost-effective and high-quality solution.\u003C/p>\u003Cp>Do you want to get started with your thermoforming project? Then enquire now using our configurator!\u003C/p>","pneumatic-forming",{"id":827,"documentId":828,"createdAt":829,"updatedAt":830,"publishedAt":831,"locale":10,"title":832,"introduction":833,"content":834,"slug":835},460,"xv9se23qc5esajjy35n4d3lw","2026-01-13T15:51:51.994Z","2026-01-26T08:45:04.319Z","2026-01-26T08:45:04.767Z","What Is a Workpiece Carrier? Definition & Applications","A constant challenge in the manufacturing industry is efficiently managing material flow throughout all assembly stages and departments. These logistical challenges can be optimally addressed by using product-specific workpiece carriers. Learn more in this article.","\u003Ch2>\u003Cspan style=\"color:#005250;\">What is a workpiece carrier?\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">A workpiece carrier, also known as a parts carrier, load carrier, tray or workpiece holder, is used to \u003Cstrong>transport\u003C/strong>, \u003Cstrong>fix\u003C/strong> and \u003Cstrong>protect\u003C/strong> workpieces during the manufacturing process. Workpiece carriers are used in various industries, including \u003C/span>\u003Ca href=\"https://www.formary.de/branchen/automotive\">\u003Cspan style=\"color:hsl(0,0%,0%);\">automotive\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">, \u003C/span>\u003Ca href=\"https://www.formary.de/branchen/elektronik-halbleitertechnologie\">\u003Cspan style=\"color:hsl(0,0%,0%);\">electronics\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">, \u003C/span>\u003Ca href=\"https://www.formary.de/branchen/nahrungsmittel\">\u003Cspan style=\"color:hsl(0,0%,0%);\">food production\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> and others.\u003C/span>\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Werkstuecktraeger_7ae6aaee4c.png\" alt=\"Werkstückträger für verschiedene Funktionen und Anwendungen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">The functions of workpiece carriers explained in more detail:\u003C/span>\u003C/h3>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Fixing and positioning\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers are used to hold the workpieces securely in place and keep them in the desired position. This is particularly important for sensitive parts.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Protection against damage\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carrier transport systems ensure that workpieces are protected during \u003C/span>\u003Ca href=\"https://www.formary.de/loesungen/kunststofftray-lagerung-transport\">\u003Cspan style=\"color:hsl(0,0%,0%);\">transport and storage\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">. Components can be fixed in such a way that sensitive component areas do not come into contact with the wall. They are also protected from falling out and vibrations during transport by fixings and customised nests.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Automation and efficiency\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In automated production systems, workpiece carriers enable a smooth material flow. Workpiece carrier systems are often designed so that they can be seamlessly integrated into automated systems and enable robotic handling. You can find more on this topic under \u003C/span>\u003Ca href=\"https://www.formary.de/loesungen/kunststoff-automatisierungstray\">\u003Cspan style=\"color:hsl(0,0%,0%);\">\"Automation trays.\"\u003C/span>\u003C/a>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">The role of workpiece carriers for Industry 4.0\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Industry 4.0 requires consistent automation of production processes for cross-technology mergers of systems. Consistent production conditions are essential to ensure that all robots and automation components can optimally control, remove and process components and transfer them smoothly to the next production step.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">These conditions are guaranteed by the use of flexible workpiece carriers, among other things.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers can efficiently transport partially processed components, assemblies or products from one cell, machine or system to the next processing station. The tray is perfectly matched to the individual conveyor technology and the respective processes. The workpiece carrier usually moves along the production line on a conveyor belt or workpiece conveyor.\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How do workpiece carriers ensure optimised production and logistics?\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers play a decisive role in the optimisation of manufacturing and logistics processes. Here are some aspects of how they can contribute to this:\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Coding and product recognition\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Various electronic and optical methods are available to ensure that machines and systems can recognise both components and the workpiece carrier.\u003C/span>\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Codierung_und_Produkterkennung_bei_Werkstuecktraegern_04b5ca29d0.png\" alt=\"Werkstückträger ermöglichen Codierung und Produkterkennung\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Placeholders for adhesive labels or label pockets\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Replaceable or fixed labels are an effective and frequently used method of product labelling. For labels, space can be saved at an early stage on the tray edge and the stacking cams can be designed to fit around them.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Integrated RFID transponders\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Electronic devices that transmit data wirelessly via radio frequencies can be integrated into the workpiece carrier. It is possible to provide space for an RFID transponder or alternative tracking devices at an early stage on the edge of the workpiece carrier.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Coding strip\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">For mechanical testing, BCD coding with moulded studs or milled cuts can be applied to the edge of the part carrier or the frame.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Colour stripes\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">An additional coloured stripe on the workpiece carrier can be used for visual alignment and orientation. Images and more information on \u003C/span>\u003Ca href=\"https://www.formary.de/produkte/tray-mit-farbstreifen\">\u003Cspan style=\"color:hsl(0,0%,0%);\">trays with colour strips\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> can be found on our product pages.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Alignment and positioning\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">To ensure that the sensor system reliably recognises components and prevents the robot gripper from colliding during loading and unloading, the workpiece carrier offers various solutions.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Gripper and fork recesses\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">If trays need to be separated individually (with a fork or grippers), recesses or grooves can be provided for dipping.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Recesses for centring cones\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Recesses for centring cones can be attached to the edge of the nest to align the workpiece carriers. The centring bar is used to secure the workpiece carrier during loading and unloading or on the conveyor belt.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Poka-Yoke corners\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The term \"poka-yoke\" comes from the Japanese and means \"avoid mistakes\". Poka-yoke corners are used for visual orientation to avoid errors such as incorrect insertion or alignment of the workpiece holder. For correctly aligned workpiece holder insertion, a chamfer can be made in one of the corners or a coloured stripe can be placed on one side.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Anti-twist protection / stacking protection\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">An anti-twist device guarantees correct alignment when stacking several workpiece carriers on top of each other by means of mechanical stacking protection. This can also be designed for different tray variants so that the workpiece carriers can only be stacked by type.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transport\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers also support the transport of components. The transport of components using the trays is ensured by efficient stacking, adaptation to conveyor systems and ergonomic handling.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:31.32%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Stapelung_von_Werkstuecktraegern_e6a854e2e3.jpg\" alt=\"Effiziente Stapelung durch Werkstückträger\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Stacking technology\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers are stackable. They can be stacked on top of each other effortlessly and stably without external aids. Various stacking techniques are available, including \u003Cstrong>undercut\u003C/strong> or \u003Cstrong>dimple stacking\u003C/strong>, which can be flexibly adapted to your transport and handling requirements.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">It is important to consider the following aspects in the design:\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">The sensitivity of the parts\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">The desired number of layers\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">The maximum height of the packaging unit\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The deep-drawn workpiece carriers can be designed so that they can be stacked free-standing on Euro pallets or integrated into cartons or small load carriers. The stacking is adapted to the palletising system used and also includes an anti-twist device for stacking protection. You can find even more information on \u003C/span>\u003Ca href=\"https://www.formary.de/blog/transportschaeden-vermeiden-mithilfe-dieser-4-stapeltechniken\">\u003Cspan style=\"color:hsl(0,0%,0%);\">stacking techniques\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> in our blog.\u003C/span>\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Adaptation to conveyor systems\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Conveyor belt systems are used in the form of roller conveyors, belt conveyors and floor conveyors. The underside of your workpiece carrier is designed according to the requirements of your transport system.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:28.45%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Anpassung_an_Foerdersysteme_2188301975.png\" alt=\"Anpassung der Werkstückträger an Fördersysteme\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Ergonomic handling\u003C/span>\u003C/h4>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Ergonomically designed \u003Cstrong>recessed grips\u003C/strong> on the sides of the workpiece carriers facilitate ergonomic loading of the trays in the KLT or outer carton. This means that the trays can be easily gripped, held, carried, removed from the carton or placed back into the carton.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:22.45%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Griffmulden_des_Werkstuecktraegers_1_0b09491900.jpg\" alt=\"Griffmulden ermöglichen ergonomisches Handling der Werkstückträger\">\u003C/figure>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">It is advisable to consider the size and position of the handles on the workpiece carrier at an early stage, as this also influences the shape of the nests and the stacking.\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why plastic workpiece trays? The advantages\u003C/span>\u003C/h2>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Blog_Banner_1_1_05bdbbe651.png\" alt=\"Gefüllter Kunststoff Werkstückträger mit Bauteilen\">\u003C/figure>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carriers can be made of various materials, including \u003C/span>\u003Ca href=\"https://www.formary.de/blog/vergleich-kunststoff-vs-metall\">\u003Cspan style=\"color:hsl(0,0%,0%);\">\u003Cstrong>plastic\u003C/strong> or \u003Cstrong>metal\u003C/strong>.\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> Plastic carriers are lighter and easier to handle than conventional metal cleaning baskets. The plastic material of the workpiece carriers therefore makes handling easier and, due to the plastic properties, promotes gentle handling of the sensitive workpieces.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Depending on the area of application, plastic workpiece carriers are usually made of materials such as PET-A, PS or ABS. Plastic trays often have special properties such as\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/blog/esd-trays-aus-kunststoff-einsatz-und-vorteile\">\u003Cspan style=\"color:hsl(0,0%,0%);\">ESD protection\u003C/span>\u003C/a>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">resistance to chemicals\u003C/span>\u003C/li>\u003Cli>\u003Cspan style=\"color:hsl(0,0%,0%);\">or integration into cleaning processes.\u003C/span>\u003C/li>\u003C/ul>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">The service life (disposable or reusable, over months or years) of the load carrier influences the design of the workpiece carrier. Thanks to variable material thicknesses, plastic pallets can be designed to be either very stable, durable and resilient for \u003Cstrong>reusable use\u003C/strong> as returnable packaging.\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:25.88%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefzieh_Transport_Einweg_Mehrweg_1dfc761d52_aca5821727.jpg\" alt=\"Einsatzdauer von Werkstückträgern\">\u003C/figure>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">This is achieved through increased material thicknesses and stabilising elements such as ribbing and struts. Alternatively, plastic workpiece carriers can be designed for \u003Cstrong>single-use\u003C/strong> in an extremely material-saving and cost-effective way.\u003C/span>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Areas of application for plastic workpiece carriers\u003C/span>\u003C/h3>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Find out more about the areas of application for plastic workpiece carriers:\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/produkte/esd-werkstuecktraeger-fuer-elektronik\">\u003Cspan style=\"color:hsl(0,0%,0%);\">ESD workpiece carriers for electronics\u003C/span>\u003C/a>\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/produkte/tray-mit-farbstreifen\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Tray with colour stripes\u003C/span>\u003C/a>\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/produkte/werkstuecktraeger-fuer-automotive-1\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Workpiece carrier for automotive\u003C/span>\u003C/a>\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/produkte/tray-verpackung-fuer-metallteile\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Tray packaging for metal parts\u003C/span>\u003C/a>\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Workpiece carriers enable efficient processes - A summary\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">In the world of manufacturing, workpiece carriers are indispensable aids that ensure the smooth running of production processes. From fixing and positioning to protection against damage, they fulfil various functions to optimise the quality of the end products and increase efficiency.\u003C/span>\u003C/p>\u003Cp>\u003Cspan style=\"color:hsl(0,0%,0%);\">Do you need workpiece carriers or\u003C/span>\u003Ca href=\"https://www.formary.de/en/products/thermoformed-plastic-packaging\">\u003Cspan style=\"color:hsl(0,0%,0%);\"> thermoformed plastic packaging \u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\">for your components? Then \u003C/span>\u003Ca href=\"https://www.formary.de/konfigurator\">\u003Cspan style=\"color:hsl(0,0%,0%);\">configure\u003C/span>\u003C/a>\u003Cspan style=\"color:hsl(0,0%,0%);\"> your plastic tray now!\u003C/span>\u003C/p>","what-is-a-workpiece-carrier",{"id":837,"documentId":838,"createdAt":839,"updatedAt":840,"publishedAt":841,"locale":10,"title":842,"introduction":843,"content":844,"slug":845},454,"tudg9nipwzcuck9nhsk43pad","2026-01-13T15:51:50.846Z","2026-01-26T08:42:40.440Z","2026-01-26T08:42:40.498Z","What is Plastic Vacuum Forming? A Brief Explanation of Vacuum Thermoforming","Vacuum forming is a method that uses vacuum and compressed air to shape plastic parts from rolls or sheets. In this process, also known as vacuum thermoforming, the vacuum pump plays a crucial role. In this article, we explain the key aspects of the vacuum forming process.","\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does Plastic Vacuum Forming Work?\u003C/span>\u003C/h2>\u003Cp>Vacuum and compressed air are used in \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic thermoforming\u003C/strong>\u003C/span> and \u003Cspan style=\"color:#005250;\">\u003Cstrong>twin-sheet processes\u003C/strong>\u003C/span> to shape thermoformed parts from rolls or sheets. While vacuum forming creates a vacuum to shape the material, \u003Cspan style=\"color:#005250;\">\u003Cstrong>pressure forming\u003C/strong>\u003C/span> additionally uses compressed air to apply greater force during the forming process. This blog post focuses on the former. Vacuum thermoforming is the oldest plastic forming method and is still widely used today. Many machine manufacturers and processors specialize in vacuum forming.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Are Molds for Vacuum Forming Made?\u003C/span>\u003C/h2>\u003Cp>A \u003Cstrong>vacuum pump\u003C/strong> creates negative pressure to pull the semi-finished plastic onto the mold. The required vacuum for the forming process is generated by the vacuum pump, typically at around one bar. This process removes air between the material and the mold surface.\u003C/p>\u003Cp>A common issue in plastic vacuum forming is that the vacuum pressure decreases when the heated material is applied to the mold. However, this phase requires the highest forming pressure. A \u003Cstrong>two-stage vacuum system\u003C/strong> can optimize this process, requiring a high-capacity vacuum pump. In this method, a second vacuum is generated before the material cools, allowing better distribution of the material into the mold’s corners and achieving sharper contours.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Vereinfachte_Prozessdarstellung_vom_Kunststoff_Vakuumformen_a055495681.png\" alt=\"Vereinfachter Darstellungsprozess vom Kunststoff Vakuumformen\">\u003Cfigcaption>Simplified representation of the plastic vacuum forming process\u003C/figcaption>\u003C/figure>\u003Cp>Even small radii can be achieved. While vacuum forming has disadvantages compared to pressure forming when producing large series and complex geometries, it is sufficient for \u003Cstrong>simpler parts\u003C/strong> and \u003Cstrong>small production runs\u003C/strong>. Due to the low forming pressure, vacuum forming is particularly suitable for relatively simple parts, such as \u003Cstrong>plastic inlays\u003C/strong> for packaging or \u003Cstrong>plastic trays for food\u003C/strong>.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Possibilities and Limitations of Plastic Vacuum Forming\u003C/span>\u003C/h2>\u003Cp>Plastic vacuum forming is highly advantageous for producing plastic parts, especially for simple parts and small quantities. Tooling costs remain affordable due to the simpler mold design compared to pressure forming tools. Additionally, vacuum forming has lower energy costs, as vacuum usage consumes less energy than compressed air forming. These advantages make vacuum forming a well-established method used successfully in various industries for a wide range of applications.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Vacuum Forming: Pros and Cons\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cstrong>Advantages of Plastic Vacuum Forming\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Disadvantages of Plastic Vacuum Forming\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Suitable for simple parts\u003C/td>\u003Ctd>Lower form sharpness compared to pressure forming\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Low tooling costs\u003C/td>\u003Ctd>Higher risk of blemishes compared to pressure forming\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Lower energy consumption than pressure forming\u003C/td>\u003Ctd>Lower temperature resistance than pressure forming\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Cost-effective for small production runs\u003C/td>\u003Ctd>Longer cycle times than pressure forming\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp>It is essential to consider the overall cost calculation. This means that when choosing plastic vacuum forming, both tooling and part costs should be carefully evaluated.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Plastic Vacuum Forming – A Conclusion\u003C/span>\u003C/h3>\u003Cp>Plastic vacuum forming is a cost-effective and efficient solution for manufacturing plastic parts. It is particularly well-suited for simple parts, small production runs, and applications such as packaging inlays or food trays. Its advantages, including cost-efficient tooling, energy efficiency, and versatile usability, make vacuum forming a popular choice across various industries.\u003C/p>\u003Cp>Do you have questions or want to produce your thermoformed product using vacuum forming? Contact us or submit an inquiry via our configurator.\u003C/p>","vacuum-forming",{"id":847,"documentId":848,"createdAt":849,"updatedAt":850,"publishedAt":851,"locale":10,"title":852,"introduction":853,"content":854,"slug":855},421,"bzmi85ikxzegn669893of6r7","2026-01-13T15:51:44.527Z","2026-01-26T08:26:02.904Z","2026-01-26T08:26:03.110Z","What is Recyclate? Options in Plastic Recycling and Distinction from Virgin Material","In an increasingly sustainability-oriented world, recycling and the reuse of materials play a key role. Plastic recyclates offer a sustainable alternative to virgin materials. But what exactly does the term mean, and how can recyclates be distinguished from virgin materials? Read more now.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Use of recyclates: status quo in Germany\u003C/span>\u003C/h2>\u003Cp>The recycling of plastics is becoming increasingly important in Germany in order to reduce the environmental impact of plastic waste. Currently, around 50% of plastic waste is recycled, while the rest is utilised for energy recovery or sent to landfill.\u003C/p>\u003Cp>In order to increase the recycling rate, the Packaging Act was therefore introduced in 2019, which obliges companies to make their packaging more environmentally friendly and ensure its disposal.\u003C/p>\u003Cp>The use of recycled plastics is also becoming increasingly popular. The circular economy should be supported by optimum packaging design (design for recycling) in order to minimise the environmental impact and at the same time ensure optimum product packaging - ideally with the highest possible proportion of recyclate.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is a recyclate?\u003C/span>\u003C/h2>\u003Cp>Recyclates are products that are created through the recycling process and are literally described as \u003Cstrong>\"reintroduced into the cycle\"\u003C/strong>. They are obtained from various materials such as glass, paper or batteries.\u003C/p>\u003Cp>In the context of plastics, recyclate is \u003Cstrong>recycled plastic material\u003C/strong> such as PE (polyethylene), \u003Ca href=\"https://www.formary.de/en/materials/pp-plastic\">PP \u003C/a>(polypropylene) or \u003Ca href=\"https://www.formary.de/en/materials/pet-a-plastic\">PET \u003C/a>(polyethylene terephthalate) that has already been disposed of once by households or businesses and is now used again to manufacture new products.\u003C/p>\u003Cp>This closes the material cycle. Plastic recyclates exist in the form of granulate, flakes or powder and are regarded as secondary raw materials.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Rezyklat_in_Form_von_Kunststoffflakes_64e7a6f185.png\" alt=\"Rezyklat in Form von Kunststoffflakes\">\u003Cfigcaption>Recyclate in the form of plastic flakes\u003C/figcaption>\u003C/figure>\u003Cp>There are \u003Cstrong>two main types\u003C/strong> of recyclates:\u003C/p>\u003Col>\u003Cli>\u003Cstrong>Post-industrial recyclates (PIR) or pre-consumer recyclates:\u003C/strong> these are created from excess plastic waste generated during the production of plastic packaging or other plastic products.\u003C/li>\u003Cli>\u003Cstrong>Post-consumer recyclates (PCR):\u003C/strong> In contrast, PCR consists of recycled plastic waste that has been used in households, industry or commerce and subsequently disposed of via the yellow bag or yellow bin.\u003C/li>\u003C/ol>\u003Ch2>\u003Cspan style=\"color:#005250;\">Recyclates: challenges in plastic thermoforming\u003C/span>\u003C/h2>\u003Cp>The use of recyclates always makes sense from a recycling perspective. However, the processing of recyclates is also associated with challenges that need to be taken into account, especially in the case of visually or technically sophisticated \u003Ca href=\"https://www.formary.de/en/products\">thermoformed products\u003C/a>:\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:23.24%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Probleme_Icon_ed57dd64a9.png\" alt=\"Probleme bei Rezyklaten_Icon\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">No uniform colour standards\u003C/span>\u003C/h3>\u003Cp>Plastics based on recyclates do not have uniform colour standards. Various regenerative components are mixed during the manufacturing process, which means that no RAL colour shade is possible.\u003C/p>\u003Cp>For example, the colour palette for \"PS Regenerat black\" ranges from anthracite to black and for \"PS Regenerat white\" from a yellowish to a bright white. There is therefore \u003Cstrong>no guarantee \u003C/strong>of colour accuracy.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Processing\u003C/span>\u003C/h3>\u003Cp>Recycled materials can be \u003Cstrong>less reliable\u003C/strong> to process than virgin material. This is because recyclates can come from a variety of sources and have different compositions from batch to batch. This can lead to variations in material properties, such as melting point, flow behaviour and mechanical properties.\u003C/p>\u003Cp>During the recycling process, materials may be subject to some degradation, especially if they have been recycled several times. This degradation can lead to a deterioration in material properties.\u003C/p>\u003Cp>Due to the differences in material composition and quality, different processing parameters may be required to process recyclates effectively. This includes changes to the processing temperature, speed or compressed air.\u003C/p>\u003Cp>As a result of the changing parameters for recycled material, recycled material may have a higher reject rate and longer cycle times compared to new material in order to achieve a similar quality. Chipping of the milling edge is also a more or less common problem with recycled material, depending on the quality of the material.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Surface quality\u003C/span>\u003C/h3>\u003Cp>Due to the variety of raw materials used, there is no guarantee for the surface quality of the deep-drawn part.\u003C/p>\u003Cp>\u003Cstrong>Complex moulds\u003C/strong> with the use of recycled materials can be problematic. This is a particular problem with deep-drawn parts, such as \u003Ca href=\"https://www.formary.de/en/solutions/plastic-covers\">plastic housings\u003C/a>, where aesthetics play a role.\u003C/p>\u003Cp>\u003Cstrong>Problems that can occur on the surface are\u003C/strong>\u003C/p>\u003Cul>\u003Cli>Air pockets\u003C/li>\u003Cli>Small bubbles\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">No material data sheet\u003C/span>\u003C/h3>\u003Cp>It is important to note that the \u003Cstrong>exact origin\u003C/strong> of the various recycled components is \u003Cstrong>not always known\u003C/strong>. It is therefore not possible to guarantee the absence of silicone. Important: The mechanical properties of individual extrusion batches can usually be determined using laboratory samples. This no longer applies to the next series from a different material batch.\u003C/p>\u003Cp>This means that there is no material data sheet available that can be used to trace the origin of the plastics.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Overview: Comparison of recycled plastic and virgin material\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Recycled plastic\u003C/th>\u003Cth>Plastic virgin material\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>No RAL colour possible\u003C/td>\u003Ctd>RAL colour possible\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>No uniform colour standards\u003C/td>\u003Ctd>High colour accuracy\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Potential bubbles and air pockets\u003C/td>\u003Ctd>Smooth surfaces\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Exact origin of the recycled components not known\u003C/td>\u003Ctd>Origin known\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>No material data sheet available\u003C/td>\u003Ctd>Material data sheet available\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Potential degradation\u003C/td>\u003Ctd>Consistent quality at all times\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp> \u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How is recyclate produced?\u003C/span>\u003C/h2>\u003Cp>The conversion of waste into recyclates takes place in a \u003Cstrong>multi-stage process.\u003C/strong> To produce recyclates, recyclable plastic products such as packaging are first disposed of in the Yellow Bag or Yellow Bin rather than in residual waste, meaning that they are recycled at least once. The pre-sorted waste is then taken to recycling centres where it is separated by type of plastic and colour using modern sorting systems.\u003C/p>\u003Cp>Once the used plastic has been sorted by type, further processing steps follow. The used plastic is pressed, shredded or both are carried out one after the other. It is then thoroughly cleaned to remove foreign plastics or other foreign materials. The recycled plastic is then ready for further use.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What is the difference between recyclate, regranulate and reclaim?\u003C/span>\u003C/h3>\u003Cp>Recyclate is the \u003Cstrong>generic term\u003C/strong> for regranulate and reclaim.\u003C/p>\u003Cp>\u003Cspan style=\"color:#0c0c0c;\">\u003Cstrong>Regranulate:\u003C/strong>\u003C/span>\u003Cspan style=\"color:#00a9a5;\"> \u003C/span>Depending on requirements and subsequent use, it may be necessary to produce regranulate from the used plastic. Recycled pellets are obtained from recyclable plastics without additives - from the ground, shredded plastics via a melting process.\u003C/p>\u003Cp>\u003Cspan style=\"color:#0c0c0c;\">\u003Cstrong>Regenerate\u003C/strong>\u003C/span>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>:\u003C/strong>\u003C/span> Regenerate is also produced by a melting process (compounding). By adding additives, various properties of the \u003Ca href=\"https://www.formary.de/en/materials\">materials \u003C/a>can be defined and customised according to requirements.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Recyclates in thermoforming\u003C/span>\u003C/h4>\u003Cp>In the thermoforming sector, recycled plastic is used as a raw material for the production of \u003Ca href=\"https://www.formary.de/en/roll-production\">plastic films\u003C/a> and \u003Ca href=\"https://www.formary.de/en/sheet-production\">sheets \u003C/a>by means of \u003Ca href=\"https://www.formary.de/en/blog/plastic-extrusion\">plastic extrusion\u003C/a>, which can then be used for the \u003Ca href=\"https://www.formary.de/en/plastic-thermoforming\">thermoforming of plastic\u003C/a>.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How is recycled material labelled?\u003C/span>\u003C/h2>\u003Cp>To label plastics that have already undergone a recycling process and are therefore different from primary plastics, the letter \"R\" is often placed in front of the material name. For example, rPET, rPP, rHDPE, rLDPE and so on. In this context, the \"R\" stands for \"recycled\" and is often written in lower case.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Legal requirements for recyclates\u003C/span>\u003C/h3>\u003Cul>\u003Cli>REACH Regulation (EC) No. 1907/2006 - REACH conformity\u003C/li>\u003Cli>RoHS Directives (EU) No. 2011/65 and Annex ⅠⅠ according to Directive (EU) No. 2015/863 - RoHS conformity\u003C/li>\u003Cli>All requirements of Annex XVII of the REACH Regulation regarding restrictions\u003C/li>\u003Cli>The Waste Framework Directive (EC) No. 2008/98:2018 on waste\u003C/li>\u003Cli>The GS specification AfPS GS 2019:01 PAH for category 2 - Other consumer products\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic recycling with formary\u003C/span>\u003C/h2>\u003Cp>Plastic thermoformed parts are fully recyclable. All production waste, such as punching and milling waste, is collected and returned to the material cycle. New granulate is produced from these remnants, which in turn is used for the production of new films and sheets.\u003C/p>\u003Cp>The post-consumer cycle is outside the direct control of formary, as proper disposal must be carried out by the end user. If the end user is a company, all parts can be fully recycled at the end of their useful life. Therefore, formary takes back old thermoformed parts and reuses them.\u003C/p>\u003Cp>ℹ️ \u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>In our \u003C/strong>\u003C/span>\u003Ca href=\"https://www.formary.de/konfigurator\">\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>configurator\u003C/strong>\u003C/span>\u003C/a>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>, you can specify whether your plastic should be made from recycled material. Under \"Material\" you have the option of using recycled material as the desired plastic option for your thermoformed product.\u003C/strong>\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The use of recycled plastics - a summary\u003C/span>\u003C/h2>\u003Cp>The use of recyclates is widespread in the thermoforming industry and is seen as an important step towards a more sustainable use of plastics. Thermoformers generally utilise the leftover material from thermoforming and grind it up to produce the plastics as recyclates for the re-production of thermoformed parts.\u003C/p>\u003Cp>However, there are still challenges in the production of high-quality plastic products, which can have sources of error, particularly in terms of aesthetics. It is therefore always worth consulting specialists if you want to use recyclates or \u003Ca href=\"https://www.formary.de/en/blog/what-are-bioplastics\">bioplastics \u003C/a>for your thermoforming project.\u003C/p>\u003Cp>If you have any questions about the use of recyclates, please \u003Ca href=\"https://www.formary.de/en/contact\">contact us\u003C/a>! We will be happy to help you.\u003C/p>","what-is-recyclate",{"id":857,"documentId":858,"createdAt":859,"updatedAt":860,"publishedAt":861,"locale":10,"title":862,"introduction":863,"content":864,"slug":865},438,"mlnpx89wcd3xb7bjpl8rwkq0","2026-01-13T15:51:47.821Z","2026-01-26T08:34:33.067Z","2026-01-26T08:34:33.461Z","What Are Bioplastics? Definition, Applications, Advantages, and Limitations","Bioplastics are plastics that are either made from renewable raw materials or are biodegradable - or both. They offer a wide range of possible applications - but what exactly are bioplastics, how are they produced and what advantages or limitations do they have compared to traditional plastics?","\u003Ch2>\u003Cspan style=\"color:#005250;\">What are bioplastics?\u003C/span>\u003C/h2>\u003Cp>Bioplastics explained simply: Bioplastics, also known as bioplastics or technical biopolymers, are plastics that are either completely or partially made from renewable raw materials, i.e. biobased and/or biodegradable. In comparison, conventional \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic materials\u003C/strong>\u003C/span> are based on fossil raw materials.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What types of bioplastics are there?\u003C/span>\u003C/h2>\u003Cp>Bioplastics can primarily be divided into two main categories: Bio-based and biodegradable plastics. In the following section, we present some examples of bioplastics to give you an overview of the different types of bioplastics.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Biobased plastics\u003C/span>\u003C/h2>\u003Cp>What does bio-based mean? Bio-based plastics are made from biological, renewable raw materials such as corn starch, sugar cane or cellulose. Bio-based bioplastics are not necessarily biodegradable.\u003C/p>\u003Cp>Bioplastic properties, such as mouldability, hardness, elasticity, breaking strength, temperature resistance, heat resistance and chemical resistance, vary depending on the composition, manufacturing process and the addition of additives.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics Overview: Bio-based plastics\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Polylactic acid (PLA):\u003C/strong> Made from fermented plant starch and biodegradable.\u003C/li>\u003Cli>\u003Cstrong>Bio-polyethylene (bio-PE):\u003C/strong> Made from sugar cane and not biodegradable.\u003C/li>\u003Cli>\u003Cstrong>Bio-polyethylene terephthalate (bio-PET):\u003C/strong> Partly made from renewable raw materials (e.g. ethanol from sugar cane). Chemically identical to conventional polyethylene, therefore not biodegradable.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Zuckerrohr_0fbe2f9765.jpg\" alt=\"Zuckerrohr\">\u003Cfigcaption>Sugar cane\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Biodegradable plastics\u003C/span>\u003C/h2>\u003Cp>Biodegradable plastics are produced by natural processes (microorganisms such as bacteria or fungi), which can be broken down into natural substances such as water, carbon dioxide (CO2) and biomass. Bioplastics degrade under certain environmental conditions that are necessary for the activity of the microorganisms (more on this later).\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics overview: Biodegradable plastics\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Polyhydroxyalkanoates (PHA):\u003C/strong> Fermented by bacteria.\u003C/li>\u003Cli>\u003Cstrong>Polybutylene succinate (PBS):\u003C/strong> Can be produced from renewable or fossil raw materials.\u003C/li>\u003Cli>\u003Cstrong>Polycaprolactone (PCL):\u003C/strong> Made from fossil raw materials.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Pilze_aus_denen_biologisch_abbaubare_Kunststoffe_entstehen_koennen_3795d63bd6.jpg\" alt=\"Pilze, aus denen biologisch abbaubare Kunststoffe entstehen können\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics overview: Bio-based and biodegradable plastics\u003C/span>\u003C/h3>\u003Cp>Some bioplastics fulfil both criteria: The biopolymers are both biobased and biodegradable.\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Polylactic acid (PLA):\u003C/strong> Made from plant starch and biodegradable.\u003C/li>\u003Cli>\u003Cstrong>Polyhydroxyalkanoates (PHA):\u003C/strong> Fermented by bacteria from renewable raw materials and biodegradable.\u003C/li>\u003Cli>\u003Cstrong>Starch-based plastics:\u003C/strong> Made from plant starch and biodegradable.\u003C/li>\u003C/ul>\u003Ch4>Overview of all types of bioplastics\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Bioplastics category\u003C/th>\u003Cth>Bio-based plastics\u003C/th>\u003Cth>Biodegradable plastics\u003C/th>\u003Cth>Bio-based and biodegradable plastics\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Bioplastics examples\u003C/td>\u003Ctd>Bio-PE, Bio-PET, PLA\u003C/td>\u003Ctd>PHA, PBS, PCL\u003C/td>\u003Ctd>Starch-based plastics, PLA, PHA\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Raw materials\u003C/td>\u003Ctd>Renewable raw materials (e.g. sugar cane, plant starch)\u003C/td>\u003Ctd>Microorganisms, various raw materials\u003C/td>\u003Ctd>Plant starch, bacteria\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp> \u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What can bioplastics be used for? - Products made from bioplastics\u003C/span>\u003C/h2>\u003Cp>The properties of bioplastics vary depending on the raw materials used and the manufacturing processes. In principle, bioplastics can have the same properties as conventional polymers. Plastic films made of bioplastics are also produced by \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic extrusion\u003C/strong>\u003C/span> like conventional thermoplastics.\u003C/p>\u003Cp>However, bioplastics are not suitable for high-performance applications. The use of bio-based materials is restricted by limited quantities, price and qualities, based on limited raw materials and higher manufacturing costs. Currently, bioplastics can be used primarily for these applications:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Packaging material / agriculture:\u003C/span>\u003C/h3>\u003Cp>Packaging products made from compostable bioplastics, such as trays for vegetables, fruit, eggs and meat, containers for drinks and dairy products and \u003Ca href=\"https://www.formary.de/branchen/kosmetik\">\u003Cspan style=\"color:#005250;\">\u003Cstrong>cosmetics packaging\u003C/strong>\u003C/span>.\u003C/a>\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Medicine / Pharmaceuticals\u003C/span>\u003C/h3>\u003Cp>For bioplastics in \u003Cspan style=\"color:#005250;\">\u003Cstrong>medicine and pharmaceuticals\u003C/strong>\u003C/span>, the focus is on the resorbability of the products, such as suture materials or implants, which can be broken down by the body after use.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Biokunststoffe_fuer_den_medizinischen_Bereich_c221f1ca84.jpg\" alt=\"Biokunststoffe für den medizinischen Bereich\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Automotive engineering\u003C/span>\u003C/h3>\u003Cp>Bio-based materials are used in the \u003Cspan style=\"color:#005250;\">\u003Cstrong>automotive\u003C/strong>\u003C/span> sector in the \"sandwich process\". The core of the component is made of bio-based polymer, a layer of a conventional material of higher quality is used on top (e.g. for optics, haptics, functionalities).\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Bioplastics vs. plastics: advantages and disadvantages\u003C/span>\u003C/h2>\u003Cp>Bioplastics have advantages and limitations compared to conventional plastics, with the latter affecting their suitability for various applications. Here we take a detailed look at the differences and challenges of bioplastics compared to conventional thermoplastics.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics advantages\u003C/span>\u003C/h3>\u003Cp>The use of biopolymers offers a number of advantages, including\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Renewable raw materials\u003C/span>\u003C/h4>\u003Cp>Crude oil is a limited raw material. In contrast, renewable raw materials are inexhaustible. This is because bioplastics are made from raw materials such as maize, sugar cane or cellulose, which reduces dependence on fossil fuels.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Potential for lower CO2 emissions\u003C/span>\u003C/h4>\u003Cp>Starch from plants is used for the production of bioplastics. These plants extract CO2 from the atmosphere for their growth. When the bioplastic is incinerated, only the amount of CO2 previously absorbed by the plant is released. This creates a \u003Cstrong>closed CO2 cycle.\u003C/strong>\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Biodegradability\u003C/span>\u003C/h4>\u003Cp>Some bioplastics, such as PLA and PHA, are biodegradable/compostable and decompose under certain conditions (e.g. in industrial composting plants) into harmless substances such as CO2, water and biomass.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Bioplastics disadvantages\u003C/span>\u003C/h3>\u003Cp>Despite the advantages mentioned, however, there are several disadvantages that must be taken into account when assessing their environmental friendliness and practicality. Here are the main challenges and disadvantages of bioplastics in detail.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">High land requirements\u003C/span>\u003C/h4>\u003Cp>The cultivation of raw materials for bioplastics requires agricultural land that could also be used for food production. This can lead to competition for agricultural resources.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Energy and resource consumption\u003C/span>\u003C/h4>\u003Cp>Bioplastics = better environment - unfortunately this is not true in terms of energy and resource consumption. The production of bioplastics can be energy-intensive and require high water consumption, which can have a negative impact on their environmental footprint.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Degradation conditions\u003C/span>\u003C/h4>\u003Cp>Many bio-based and biodegradable plastics require special conditions (e.g. industrial composting plants) for degradation, which are not always available everywhere or require energy.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Costs\u003C/span>\u003C/h4>\u003Cp>The prices of bioplastics are often more expensive than conventional plastics, which can limit their widespread use.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Limited recycling options\u003C/span>\u003C/h4>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Kunststoffgranulat_in_den_Haenden_ff39ee0490.png\" alt=\"Kunststoffgranulat in den Händen\">\u003C/figure>\u003Cp>In contrast to conventional \u003Cspan style=\"color:#005250;\">\u003Cstrong>recycled plastics\u003C/strong>\u003C/span>, bioplastics cannot be mechanically recycled without special recycling processes that are tailored to the respective material flow. The recycling of bioplastics is therefore difficult, as biodegradable plastics often require a longer retention period in composting plants.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Bioplastics in thermoforming\u003C/span>\u003C/h2>\u003Cp>Can bioplastics now also be used for \u003Cspan style=\"color:#005250;\">\u003Cstrong>plastic thermoforming\u003C/strong>\u003C/span> and thus for \u003Cspan style=\"color:#005250;\">\u003Cstrong>trays\u003C/strong>\u003C/span>, \u003Cspan style=\"color:#005250;\">\u003Cstrong>containers\u003C/strong>\u003C/span>, \u003Cspan style=\"color:#005250;\">\u003Cstrong>inlays\u003C/strong>\u003C/span> and \u003Cspan style=\"color:#005250;\">\u003Cstrong>covers?\u003C/strong>\u003C/span> And how does bioplastic behave in contrast to conventional thermoplastics? More on this in the next sections.\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/Biokunststoffe_im_Kunststoff_Tiefziehen_e356821fc2.png\" alt=\"Biokunststoffe im Kunststoff Tiefziehen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material properties\u003C/span>\u003C/h3>\u003Cp>Bioplastics have different properties compared to conventional plastics. Some bio-based plastics, such as polylactic acid (PLA) and polyhydroxyalkanoates (PHA), are thermoplastic and can therefore theoretically be used for thermoforming.\u003C/p>\u003Cp>However, due to their different structure, bioplastics have special requirements in terms of temperature and processing that may differ from those of conventional plastics. Adapting moulding tools to the specific properties of bioplastics can therefore incur additional costs.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Processing parameters\u003C/span>\u003C/h3>\u003Cp>The processing temperatures and times for bioplastics can vary. PLA, for example, has a lower processing temperature compared to many standard plastics such as polyethylene (PE) or \u003Cspan style=\"color:#005250;\">\u003Cstrong>polypropylene (PP)\u003C/strong>\u003C/span>.\u003C/p>\u003Cp>Some bioplastics are \u003Cstrong>hygroscopic\u003C/strong>, which means that they absorb moisture from the environment. This can lead to processing problems such as bubble formation or undesirable material changes.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Mechanical properties\u003C/span>\u003C/h3>\u003Cp>Bioplastics often have different mechanical properties than traditional plastics. Some may be less impact resistant\u003Cstrong> \u003C/strong>or less elastic, which influences the choice of applications. The strength and flexibility must be carefully tested to ensure that the end products meet the requirements.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Is bioplastic an alternative? - A conclusion\u003C/span>\u003C/h2>\u003Cp>The bioplastics market share is currently around 1%. Therefore, the possibilities are far from exhausted when it comes to the use of biopolymers in thermoforming. The advantages of bioplastics are a major factor in utilising them for more applications: Biodegradability, lower CO2 emissions and resource conservation.\u003C/p>\u003Cp>However, the use of bioplastics also has its limitations and disadvantages. Not only can bioplastics not keep up with regular thermoplastics when it comes to high-performance applications. Their production can require considerable amounts of agricultural resources.\u003C/p>\u003Cp>Biopolymers often require special conditions for decomposition and are not fully degradable in conventional composting plants. In addition, there is currently a lack of efficient recycling processes, which means that incineration remains the most common disposal method. And another important factor: bioplastics are often more expensive to produce than conventional plastics, which reduces their economic attractiveness. However, if the market share of bioplastics grows and exceeds 1%, these aspects could change. We will see what the future holds for the world of bioplastics.\u003C/p>\u003Cp>ℹ️ Want to find out more about bioplastics, additives and compounds? Then read our \u003Ca href=\"https://www.formary.de/whitepaper-ebooks/materialleitfaden-fuer-kunststoff-tiefziehteile\">material guide for thermoformed plastic parts\u003C/a> or watch our video:\u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Ciframe width=\"560\" height=\"315\" src=\"https://www.youtube.com/embed/HhU0eK7A1ag?si=bjZ_Ucmgq2TH4km_\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen=\"\">\u003C/iframe>\u003C/div>\u003Cp> \u003C/p>\u003Cdiv class=\"raw-html-embed\">\u003Cdiv class=\"c-container\"> \n    \u003Cp>ℹ️ For anyone involved in developing medicine blister packs: Find out more in the\n \u003Ca href=\"https://www.formary.de/en/whitepaper-ebooks/relevance-of-thermoformed-blisters-in-medical-technology\">Whitepaper\u003C/a>, which plastics are suitable for sterile, validatable and increasingly sustainable medtech packaging – including options with bio-based materials.\n\u003C/p>\n\u003C/div>\n\u003C/div>\u003Cfigure class=\"image\">\u003Ca href=\"https://www.formary.de/en/whitepaper-ebooks/relevance-of-thermoformed-blisters-in-medical-technology\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Medical_Blister_Whitepaper_1_e5fe165fb6.png\" alt=\"Med Tech OEM Whitepaper Mockup\">\u003C/a>\u003C/figure>","what-are-bioplastics",{"id":867,"documentId":868,"createdAt":869,"updatedAt":870,"publishedAt":871,"locale":10,"title":872,"introduction":873,"content":874,"slug":875},435,"kmwdd65q4ti6vu8naxlydmsf","2026-01-13T15:51:47.224Z","2026-01-26T08:33:16.775Z","2026-01-26T08:33:17.093Z","What Stacking Methods Are Used for Trays? 4 Stacking Methods for Efficient Palletizing","This article demonstrates which stacking methods are used for different applications, where common errors occur, and which stacking method provides the greatest added value.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Palletising: How to avoid transport damage with the right stacking method\u003C/span>\u003C/h2>\u003Cp>If plastic trays and workpiece carriers can be stacked, this has advantages for production, storage and logistics. In production, your products are loaded into trays from conveyor belts until the assembled stacks are transported onwards. Free-standing tray stacks do not require any additional boxes or containers as loading aids. Stacking trays save space when storing your products. In intralogistics, a stable stacking method ensures safe transport.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">A few key facts about tray stacking methods\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:7%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_24de199cb0.png\" alt=\"Trayhöhe\">\u003C/figure>\u003Cp>If trays are to be stacked, this must be taken into account in the design, as additional space is required for stacking. A stackable tray is therefore usually slightly higher than non-stackable models. The tray height when loaded is then made up as follows, for example:\u003C/p>\u003Cp>\u003Cspan class=\"text-small\">Height of the components: 65 mm\u003C/span>\u003C/p>\u003Cp>\u003Cspan class=\"text-small\">Stacking height: 10 mm\u003C/span>\u003C/p>\u003Cp>\u003Cspan class=\"text-small\">Space to the next higher tray: 3 mm\u003C/span>\u003C/p>\u003Cp>\u003Cspan class=\"text-small\">Material thickness of the tray (wall thickness): 2 mm\u003C/span>\u003C/p>\u003Cp>\u003Cspan class=\"text-small\" style=\"color:#00a9a5;\">\u003Cstrong>Tray height (loaded): = 80 mm\u003C/strong>\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:13.65%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_5b95b4029d.png\" alt=\"Gesamt-Stapelhöhe\">\u003C/figure>\u003Cp>The \u003Cstrong>total \u003C/strong>stacking height of this example results from the calculated tray height of 80 mm (loaded) and the stacking height of 10 mm per tray added with each tray. If certain outer carton dimensions are specified, it is possible to calculate how many trays fit into a packaging unit.\u003C/p>\u003Cp>In the formary configurator, you can either adapt the tray to a specific carton or directly request a suitable carton for the specified stacking height.\u003C/p>\u003Cp> \u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which stacking method is the right one for efficient palletising?\u003C/span>\u003C/h2>\u003Cp>When selecting the right stacking method for palletising, various points are decisive:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material thickness\u003C/span>\u003C/h3>\u003Cp>The required stacking of the tray depends primarily on the material thickness used. The stacking method often depends on whether the tray is used as a disposable or reusable product.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensitivity of the products\u003C/span>\u003C/h3>\u003Cp>Can the next higher tray stack touch your components or rest on them, or are they touch-sensitive? If you are not allowed to stack over the components, but must leave a few millimetres of clearance to the next higher tray, then the stacking tray must be designed to be self-supporting - this requires robust palletising.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Urgency of the schedule\u003C/span>\u003C/h3>\u003Cp>Simple stacking techniques, such as undercut stacking, are easier to implement than moving mould parts (a nap stacking) - and therefore shorten the lead time of your first samples.\u003C/p>\u003Cp>These points determine the pallet stacking method to be used.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What exactly is an undercut? And what is it used for when palletising stacking trays?\u003C/span>\u003C/h2>\u003Cp>The most commonly used stacking method in logistics is undercut stacking.\u003C/p>\u003Cfigure class=\"image image-style-align-left image_resized\" style=\"width:8.24%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/guide_74_2_12261286b6.png\" alt=\"Relevanz vom Hinterschnitt beim Stapeln\">\u003Cfigcaption>The role of the undercut in the appropriate stacking method\u003C/figcaption>\u003C/figure>\u003Cp>An undercut is an inward-facing flange in the tray wall. These are not easy to mould during production, as they have to be removed from the thermoforming tool in the opposite direction to the demoulding direction.\u003C/p>\u003Cp>\u003Cspan style=\"color:#005250;\">However, undercuts offer considerable advantages when using plastic trays - for example, they enable cost-efficient stacking.\u003C/span>\u003C/p>\u003Cp>The size of undercuts can be varied. For small loads such as small cups, an undercut can be very narrow. However, if large loads have to be carried, for example heavy metal parts or engine components, more support surface is required so that the weight is evenly distributed over the material of the underlying tray. In this case, the undercuts are designed to be as wide and deep as possible.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The price-performance ratio of stacking methods\u003C/span>\u003C/h2>\u003Cp>So which techniques are available and which should be used to avoid transport damage? That depends. We provide guide values based on your application or product. What you are primarily interested in when purchasing a tray is often the price - or the price-performance ratio. More complex technologies often have higher tool prices. We explain the background.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#00a9a5;\">1. Stacking method for small buckets, tubs, tubs: \u003C/span>\u003Cspan style=\"color:#005250;\">Undercut stacking at the edge\u003C/span>\u003C/h2>\u003Cp>With smaller buckets and tubs, the undercut stacking does not need to be very pronounced due to the low weight. It can therefore be applied directly to the edge. This type of palletising is therefore particularly suitable for containers. Simple undercut stacking can be incorporated into the mould during design and is not cost-intensive.\u003C/p>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:black;\">\u003Cstrong>Top undercut:\u003C/strong>\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Hinterschnitt_oben_813af2698e.png\" alt=\"Hinterschnitt oben\">\u003Cfigcaption>Undercut top\u003C/figcaption>\u003C/figure>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:black;\">\u003Cstrong>Undercut bottom:\u003C/strong>\u003C/span>\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Hinterschnitt_unten_a2a0928b7e.png\" alt=\"Hinterschnitt unten\">\u003Cfigcaption>Undercut bottom\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#00a9a5;\">2. Stacking method for disposable trays and workpiece carriers with thin material:\u003C/span>\u003Cspan style=\"color:#005250;\"> undercut stacking in the wall\u003C/span>\u003C/h2>\u003Cp>We have already discussed what undercuts are. As products with a low weight only require a narrow stack, this can be incorporated into the mould without additional features (more on this later). This allows for low-cost moulds and fast production cycles. Just right for disposable trays.\u003C/p>\u003Cp>The disadvantage, however, is that undercut stacking can naturally reach its limits with thin material. If the load is too heavy and the stacking does not support it, the undercut must either be maximised or the material thickness increased. If this does not help either, dimple stacking must be used (see point 4.).\u003C/p>\u003Cp>Normal undercut stacking is usually used for transport and storage applications:\u003C/p>\u003Cul>\u003Cli>Small trays\u003C/li>\u003Cli>Workpiece carriers with low packing density\u003C/li>\u003Cli>Workpiece carriers with low weight\u003C/li>\u003Cli>Low initial thicknesses\u003C/li>\u003Cli>Disposable trays\u003C/li>\u003Cli>Lowest possible project costs\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#00a9a5;\">3. Stacking method for inlays and inserts:\u003C/span>\u003Cspan style=\"color:#005250;\"> A/B stacking\u003C/span>\u003C/h2>\u003Cp>With A/B stacking, two different versions, A and B, of the tray are produced. The two tray versions are identical, but have offset stacking lugs. When palletising, an A part is always placed on a B part so that the nubs are always positioned at offset points on the tray and stabilise the parts.\u003C/p>\u003Cp>Theoretically, this would require two different thermoforming moulds. However, it is also possible to simply use a multi-slot mould with 50% A and 50% B stacking trays. Alternatively, movable modules can be fitted in a single-use mould, which are changed after half the number of pieces. This effort has a corresponding effect on the price of A/B stacking.\u003C/p>\u003Cp>A/B stacking is often used for empty packaging during palletising. This means when empty packaging is sent to a packaging line for packing. The trays are very easy to separate, are all aligned in the same way and can be processed quickly from the stack. The usual area of application for A/B stacking is therefore the \u003Ca href=\"https://www.formary.de/en/solutions/plastic-inlays\">inlay\u003C/a>.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#00a9a5;\">4. Stacking method for automation trays:\u003C/span>\u003Cspan style=\"color:#005250;\"> Dimple stacking from a flap mould\u003C/span>\u003C/h2>\u003Cp>If the stacking has to be very stable, dimple stacking is used for palletising. The stacking trays are supported and stacked by circumferential block segments. If trays contain heavy parts or if precise stacking tolerances of the vertical stack are required (e.g. in a palletiser of an automation system), this is the right technology.\u003C/p>\u003Cp>The circumferential stacking cams are so strongly moulded that they could not be demoulded with a normal tool. For this reason, horizontal flaps are used around the edge of the mould during production to form the block segments. Before demoulding, these segments fold to the side so that the tray can be demoulded seamlessly. This technique requires a more complex mould design. A so-called flap mould with moving parts is used.\u003C/p>\u003Cp>For this reason, this stacking method tends to be in the premium range, with a more cost-intensive tool setup and longer tool production times. For this reason, flap tool stacking is usually used in higher-value application areas such as automation , where robot palletising comes into play in addition to manual palletising.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">These typical mistakes are often made when palletising\u003C/span>\u003C/h2>\u003Cp>For stacking to fulfil its purpose, a number of points have to fit together. Are you having problems stacking your trays? We discuss the error patterns and their possible causes:\u003C/p>\u003Cp>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>The aim is to prevent jammed and wedged stacks and to achieve the most stable result possible.\u003C/strong>\u003C/span>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Conclusion: The right stacking method helps to avoid transport damage\u003C/span>\u003C/h2>\u003Cp>\u003Cspan style=\"background-color:rgb(255,255,255);color:rgb(13,13,13);\">The correct stacking method helps to prevent transport damage by distributing the weight evenly and contributing to the stability of the load. Different techniques such as undercut stacking and dimple stacking contribute significantly to product safety. The choice of the right palletising technology should be tailored to the specific requirements in order to optimise costs and minimise damage.\u003C/span>\u003C/p>\u003Cp>Would you like to benefit from this? Simply tell us the stacking height or the number of trays to be stacked in your enquiry. If you already have 3D data for your tray, you can also use our \u003Cspan style=\"color:#005250;\">\u003Cstrong>3D tray generator\u003C/strong>\u003C/span> to test which stacking method is best suited to your plastic tray.\u003C/p>\u003Cp>Still have questions about tray stacking methods? Write to us in the live chat or give us a call!\u003C/p>","stacking-methods-for-trays",{"id":877,"documentId":878,"createdAt":879,"updatedAt":880,"publishedAt":881,"locale":10,"title":882,"introduction":883,"content":884,"slug":885},436,"kry9z4d9ub1c3foldtl5lm62","2026-01-13T15:51:47.416Z","2026-01-26T08:33:46.011Z","2026-01-26T08:33:46.784Z","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":887,"documentId":888,"createdAt":889,"updatedAt":890,"publishedAt":891,"locale":10,"title":892,"introduction":893,"content":894,"slug":895},446,"pfbv8mi0e4lzuu3yhe46sder","2026-01-13T15:51:49.378Z","2026-01-26T08:39:04.640Z","2026-01-26T08:39:04.691Z","Surface finishing for medical housings: Function meets design","The finishing of medical housing surfaces must meet the highest standards of functionality, hygiene, and design. This blog post will explain how formary uses thermoforming to produce visually appealing and functional medical housings ensuring compliance with regulatory requirements.","\u003Ch2>Surface optimization for thermoformed medical housings – Key facts at a glance\u003C/h2>\u003Cul>\u003Cli>Modern surfaces for thermoformed medical housings are created through a combination of \u003Cstrong>materials technology\u003C/strong> and \u003Cstrong>design \u003C/strong>and meet the highest standards of functionality and hygiene.\u003C/li>\u003Cli>\u003Cstrong>Technical refinements\u003C/strong> ensure EMC protection, flame retardancy, and UV resistance for reliable and safe use.\u003C/li>\u003Cli>\u003Cstrong>Visual optimizations\u003C/strong> create CI-compliant designs, thereby improving user-friendliness.\u003C/li>\u003Cli>\u003Cstrong>Functional refinements\u003C/strong> enhance electrical shielding and cleaning resistance and reduce germ contamination.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>What requirements must the surfaces of medical enclosures meet?\u003C/h2>\u003Cp>The surface treatment of \u003Ca href=\"https://www.formary.de/en/products/medical-covers\">medical covers\u003C/a> must withstand mechanical stress and comply with strict standards for electromagnetic compatibility (EMC), fire safety, and hygiene. In addition, the demands on design and haptics are increasing, as devices are increasingly in the field of vision or in direct contact with patients.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Medizintechnik_Gehaeuse_c095090a55.png\" alt=\"Medical cover for MSOT-Tool\">\u003Cfigcaption>Medical cover for MSOT-Tool\u003C/figcaption>\u003C/figure>\u003Ch2>How do technical refinements protect medical devices?\u003C/h2>\u003Cp>Technical \u003Ca href=\"https://www.formary.de/en/post-processing-methods/surface-treatment\">surface refinements\u003C/a>\u003Ca href=\"https://www.formary.de/nachbearbeitungsverfahren/oberflaechenbehandlung\"> \u003C/a>in \u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">medical technology\u003C/a> ensure that housings function reliably and safely. These include the following surface treatments:\u003C/p>\u003Ch3>EMC protection: How is unwanted radiation shielded? \u003C/h3>\u003Cp>EMC protection (electromagnetic compatibility) uses a conductive inner layer to shield unwanted radiation and protect sensitive electronics including ultrasound devices or ECG systems from emissions and electromagnetic interference. This EMC shielding is achieved through specialized coating processes such as conductive paints, electroplating, or vapor deposition.\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/EMV_Abschirmung_85893a197e.webp\" alt=\"EMC as an important criteria for medical covers\">\u003Cfigcaption>EMC as an important criteria for medical covers\u003C/figcaption>\u003C/figure>\u003Ch3> \u003C/h3>\u003Ch3>Flame retardancy: Why is flame resistance so important in medical technology?\u003C/h3>\u003Cp>Many medical plastic housings must comply with the UL94 V0 classification and self-extinguish within seconds in the event of a fire.\u003C/p>\u003Ch4>Which plastics offer flame retardancy?\u003C/h4>\u003Cp>Plastic housings made from material blends such as ABS-PC combinations combine the superior mechanical properties of \u003Ca href=\"https://www.formary.de/en/materials/pc-plastic\">polycarbonate \u003C/a>with the lower processing temperature and moldability of \u003Ca href=\"https://www.formary.de/en/materials/abs-plastic\">ABS \u003C/a>and are ideal for flame retardancy. This ensures that safety standards are met with optimal functionality, even for large cladding components.\u003C/p>\u003Ch3>UV protection: How is the long service life of medical housings guaranteed?\u003C/h3>\u003Cp>Medical devices are often exposed to intense lighting or direct sunlight, but can be protected by UV-resistant plastics. UV-stabilized plastics such as \u003Ca href=\"https://www.formary.de/en/materials/asa-plastic\">ASA \u003C/a>or \u003Ca href=\"https://www.formary.de/en/materials/abs-plastic\">ABS \u003C/a>prevent surfaces from yellowing, becoming brittle, or losing their mechanical properties over time. This ensures long-lasting functionality and appearance, even with intensive use.\u003C/p>\u003Ch2>What are the advantages of optical refinements in medical technology?\u003C/h2>\u003Cp>The surface of medical cladding components is much more than just a design element. It is crucial for functionality, hygiene, and user-friendliness. Cladding should not only look good but also integrate seamlessly into sterile, functional environments. The advantages:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Ease of use:\u003C/strong> Color, finish, and texture influence the ease of use and visual impact of a medical device, especially in clinical environments.\u003C/li>\u003Cli>\u003Cstrong>Recognition\u003C/strong>: CI-compliant color schemes and precise prints ensure recognition and serve as orientation aids.\u003C/li>\u003C/ul>\u003Ch3>Direct coloring for series production\u003C/h3>\u003Cp>For CI-compliant colors and logos on medical technology housings, various color options can already be integrated in the material during production for larger quantities. The desired RAL shade is \u003Ca href=\"https://www.formary.de/en/blog/plastic-extrusion\">extruded \u003C/a>directly into the plastic material using so-called masterbatches. The process is cost-efficient, but requires a minimus material volume (1-5 tons).\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/abdeckung_farbe_01_b74a6e956d.png\" alt=\"Color options for medical housings directly through pre-colored materials or painting\">\u003Cfigcaption>Color options for medical housings directly through pre-colored materials or painting\u003C/figcaption>\u003C/figure>\u003Ch3>In which cases should paint finishes be used?\u003C/h3>\u003Cul>\u003Cli>For smaller batch sizes, prototypes, or individual customer requirements, \u003Ca href=\"https://www.formary.de/en/post-processing-methods/oberflaechenbehandlung/varnishing\">paint finishes\u003C/a> offer maximum flexibility even for quantities as low as one.\u003C/li>\u003Cli>Metallic, matte, or effect paints serve to protect the surface and enhance its appearance, for example by reducing reflections.\u003C/li>\u003Cli>Film coatings such as polished metal or chrome create attractive designs to achieve a modern, easy-to-clean, and high-quality look.\u003C/li>\u003C/ul>\u003Ch3>Further options for surface finishing of medical plastic housings\u003C/h3>\u003Cp>In addition to painting and coating, the thermoforming process itself offers opportunities for targted surface design. For example, textures and patterns can be engraved directly into the tooling. This allows fine leather-like patterns, grooves, or microtextures to be transferred to the component surface during forming.\u003C/p>\u003Cp>\u003Cstrong>The result:\u003C/strong> glare-free, non-slip, and easy-to-clean surfaces that are ideal for surgical environments or diagnostic workstations.\u003C/p>\u003Ch2>What advantages do functional finishes offer for medical enclosures?\u003C/h2>\u003Cp>Beyond design and safety, medical device surfaces must also meet specific functional requirements. These include:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Electroplating\u003C/strong>: Electroplated metal layers enhance electrical conductivity and mechanical strength. This is important for enclosure components that require electrical conductivity or must withstand high mechanical loads.\u003C/li>\u003Cli>\u003Cstrong>Vapor-deposited and uniformly metallized surfaces: \u003C/strong>These provide a high-quality, decorative appearance, as is often required for bezels or decorative panels in medical devices.\u003C/li>\u003Cli>\u003Cstrong>Antimicrobial additives: \u003C/strong>Antimicrobial additives such as silver ions, zinc oxide, or copper-based solutions reduce germ contamination.\u003C/li>\u003Cli>\u003Cstrong>Fluorination & gamma irradiation\u003C/strong>: Processes such as fluorination or gamma irradiation specifically alter surface properties.\u003C/li>\u003C/ul>\u003Cp>\u003Cstrong>However, it is important to note: \u003C/strong>Such additives do not replace regular cleaning, which is why resistance to disinfectants is a key criterion in the selection of materials.\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/Hygieneanforderungen_an_medizinischen_Gehaeusen_02f8c6f1b6.webp\" alt=\"Color options for medical housings directly through pre-colored materials or painting\">\u003Cfigcaption>Color options for medical housings directly through pre-colored materials or painting\u003C/figcaption>\u003C/figure>\u003Chr>\u003Ch2>Frequently asked questions about surface finishing in medical technology\u003C/h2>\u003Ch4>What is surface finishing in medical enclosures?\u003C/h4>\u003Cp>This refers to the targeted treatment of plastic surfaces to optimize properties such as conductivity, texture, and appearance. This makes thermoformed medical housings more durable, safer, and easier to use.\u003C/p>\u003Ch4>Which plastics are suitable for the surfaces of medical technology housings?\u003C/h4>\u003Cp>Polycarbonate (PC), ABS, and ASA are among the plastics suitable for medical technology housings, with material blends such as ABS-PC combinations being particularly common.\u003C/p>\u003Ch4>How do surfaces influence the function of medical devices?\u003C/h4>\u003Cp>The surface significantly determines the safety, hygiene, usability, and durability of medical devices.\u003C/p>\u003Ch4>How do I choose the right surface finish for my medical enclosure?\u003C/h4>\u003Cp>The choice of the appropriate finish depends on the application environment, quantity, and design and functional requirements. formary will advise you individually on this.\u003C/p>\u003Chr>\u003Ch2>Optimize the surface of your medical device housing now\u003C/h2>\u003Cp>The surface defines more than just the appearance: it also affects hygiene, safety, functionality, and user experience. With the right materials and processes from formary, you get functional and economically viable solutions for thermoformed components used in medical applications.\u003C/p>\u003Cp>Request your thermoformed \u003Cstrong>medical housings\u003C/strong> directly through the formary \u003Ca href=\"https://www.formary.de/en/configurator\">configurator \u003C/a>and kick-tart your next project.\u003C/p>","surface-finishing-for-medical-housings",{"id":897,"documentId":898,"createdAt":899,"updatedAt":900,"publishedAt":901,"locale":10,"title":902,"introduction":903,"content":904,"slug":905},463,"yt35yx2a2ob138xd444o1cxl","2026-01-13T15:51:52.616Z","2026-01-26T08:46:19.075Z","2026-01-26T08:46:19.982Z","Plastic manufacturing processes compared: thermoforming vs. injection molding, 3D printing, CNC milling, and foam","When manufacturing plastic parts, thermoforming is often compared with injection molding, milling, 3D printing, and foam solutions. The decisive factors are speed, cost, design freedom, material requirements, and process reliability. This article highlights the key differences between these processes.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Comparison of plastic manufacturing processes - The most important facts in brief\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Plastic manufacturing processes differ primarily in terms of time-to-market, costs, design freedom, robustness, material diversity, and automatability.\u003C/li>\u003Cli>\u003Cstrong>Thermoforming\u003C/strong> is particularly advantageous for small to medium series and offers short project lead times.\u003C/li>\u003Cli>\u003Cstrong>Injection molding\u003C/strong> is worthwhile for large quantities, but incurs high tooling costs.\u003C/li>\u003Cli>\u003Cstrong>Milling and 3D printing\u003C/strong> are suitable for prototyping, but are expensive in series production.\u003C/li>\u003Cli>\u003Cstrong>Foam and standard solutions\u003C/strong> are cost-effective, but technically limited.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What are the most important plastic manufacturing processes?\u003C/span>\u003C/h2>\u003Cp>In plastics engineering, different plastic processes are used depending on the component geometry and quantity.\u003C/p>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Process\u003C/th>\u003Cth>Category\u003C/th>\u003Cth>Typical applications\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Thermoforming\u003C/td>\u003Ctd>Forming\u003C/td>\u003Ctd>Housings, covers, trays, packaging\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Injection molding\u003C/td>\u003Ctd>Casting\u003C/td>\u003Ctd>Mass-produced products, precision components\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>CNC milling\u003C/td>\u003Ctd>Machining\u003C/td>\u003Ctd>Precision components, prototypes\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>3D printing\u003C/td>\u003Ctd>Additive\u003C/td>\u003Ctd>Prototypes, small series, complex geometries\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Foam solutions\u003C/td>\u003Ctd>Foaming\u003C/td>\u003Ctd>Upholstery, simple packaging\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp>In plastics engineering, these processes are primarily differentiated according to the molding method, quantity, precision, and material properties.\u003C/p>\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 In this article, we compare plastic manufacturing processes that are particularly suitable for housings, covers, trays, and functional components. Processes such as extrusion or blow molding are deliberately not covered in depth, as they are primarily used for profiles, films, or hollow bodies without specific geometries. \u003C/p>\n    \u003C/div>\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">How do key plastic manufacturing processes work?\u003C/span>\u003C/h2>\u003Cp>Here is a brief overview of how they work:\u003C/p>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>In \u003Ca href=\"https://www.formary.de/en/plastic-thermoforming\">thermoforming\u003C/a>, a plastic sheet is heated and then drawn into a mold. The process is suitable for \u003Ca href=\"https://www.formary.de/en/solutions/plastic-containers\">containers\u003C/a>, \u003Ca href=\"https://www.formary.de/en/solutions/plastic-covers\">housings\u003C/a>, \u003Ca href=\"https://www.formary.de/en/products/thermoformed-plastic-packaging\">packaging\u003C/a>, and \u003Ca href=\"https://www.formary.de/en/solutions/plastic-inlays\">inlays\u003C/a>.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Isometric_view_1_1_30bffb92d9.webp\" alt=\"Isometric view of the thermoforming process\">\u003C/figure>\u003Ch3>Injection molding\u003C/h3>\u003Cp>In \u003Ca href=\"https://www.formary.de/en/blog/injection-molding-vs-thermoforming\">injection molding\u003C/a>, plastic is first melted and then injected under pressure into a closed mold. There, the material solidifies through controlled cooling before the mold is opened and the component is removed.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Filling_funnel_1_1_99ee04589a.webp\" alt=\"Injection molding process\">\u003C/figure>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>In \u003Ca href=\"https://www.formary.de/en/post-processing-methods/trennen/cnc-milling\">CNC milling\u003C/a>, a component is carved out of a plastic block by a computer-controlled milling head that precisely removes material along predetermined paths.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_12_1_c0eee05c68.webp\" alt=\"CNC milling process\">\u003C/figure>\u003Cp>In \u003Ca href=\"https://www.formary.de/en/blog/thermoforming-vs-3d-printing\">3D printing\u003C/a>, also known as additive manufacturing, a component is built up layer by layer from plastic.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Material_preparation_1_1_ef5d47864c.webp\" alt=\"3D printing process\">\u003C/figure>\u003Ch4>Foam and standard solutions\u003C/h4>\u003Cp>Foam can be produced both chemically and physically. In chemical foaming, typical components such as polyol and isocyanate react with each other, producing CO₂ among other things. This gas causes the mass to foam. In physical foaming, a blowing agent is added which expands or evaporates when heated, thus forming the pore structure.\u003C/p>\u003Cp>After foaming, the foam block hardens and can then be cut, punched, or CNC-machined. The foam parts produced in this way are particularly suitable for simple packaging, upholstery elements, or standard solutions.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">The top 5 factors to consider when deciding which plastic manufacturing process is best suited to your application\u003C/span>\u003C/h2>\u003Cp>The processes are compared in five categories that are often decisive when it comes to the production of plastic parts:\u003C/p>\u003Col>\u003Cli>Time to market\u003C/li>\u003Cli>Cost structure (for small and medium series)\u003C/li>\u003Cli>Design freedom & modification effort\u003C/li>\u003Cli>Mechanical robustness\u003C/li>\u003Cli>Material selection\u003C/li>\u003C/ol>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Time-to-market\u003C/span>\u003C/h3>\u003Cp>Fast development and production start-ups enable you to respond to market requirements. Especially in dynamic markets, a short time-to-market can be crucial for securing competitive advantages or meeting project deadlines.\u003C/p>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>In the best case scenario, a \u003Ca href=\"https://www.formary.de/en/blog/project-planning-in-thermoforming\">thermoforming project\u003C/a> can be delivered in less than 6 weeks. This includes 1-2 weeks for creating the design based on the requirements and data in consultation with the company. Once the \u003Ca href=\"https://www.formary.de/en/blog/construction-data-in-thermoforming\">design data\u003C/a> has been approved, production of the aluminum series tool begins. Depending on the urgency, this can be done in 3 weeks.\u003C/p>\u003Cp>As soon as the \u003Ca href=\"https://www.formary.de/en/blog/tools-for-thermoformed-plastic-parts\">tool\u003C/a> is ready, it is taken to the thermoforming manufacturer and the first samples are drawn from the series tool and material. Once the series samples have been approved, series production begins. Depending on the quantities and provided that the manufacturer has sufficient capacity, (partial) delivery can take place after just two weeks.\u003C/p>\u003Ch4>Injection molding\u003C/h4>\u003Cp>In injection molding, the long tooling times of usually six to twelve weeks lead to a significantly delayed start of series production.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/CW_1_2_1_1_0515b9ec9d.webp\" alt=\"Delivery times in injection molding\">\u003C/figure>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>Milling and 3D printing are becoming increasingly complex in series production, which means that production times are longer overall. 3D printing is very fast for smaller quantities or prototypes, as no tools are required. This means there are \u003Cstrong>no lead times\u003C/strong>. Once the CAD data is available, parts can be manufactured within a few days.\u003C/p>\u003Cp>For large series, 3D printing or milling is limited due to slower production speeds, poor scalability, and higher material costs.\u003C/p>\u003Ch4>Foam / Standard solutions\u003C/h4>\u003Cp>Foam and standard solutions are ready for immediate use, but often do not offer the precision required for technically demanding applications.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Cost structure for small and medium series\u003C/span>\u003C/h3>\u003Cp>In moderate quantities, fixed costs have a direct impact on profitability, as they significantly increase the unit price. Processes with low fixed costs enable more efficient unit costs and reduce the risk of an uneconomical series.\u003C/p>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>A key cost driver in a thermoforming project is the tooling costs, which represent a one-time investment in the four to five-digit range. These costs are amortized as the number of units increases. Since economies of scale do not apply to the same extent to material costs, the proportion of material costs per thermoformed part increases with increasing quantity and thus becomes the largest cost center.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Total_cost_share_1_1_079ca23bfa.webp\" alt=\"Cost factors in thermoforming\">\u003C/figure>\u003Cp>Compared to other plastic manufacturing processes, thermoforming occupies the “sweet spot” between several hundred and 10,000 parts, as the initial tooling costs are significantly lower than for injection molding and the unit prices are significantly lower than for 3D printing.\u003C/p>\u003Ch4>Injection molding\u003C/h4>\u003Cp>Injection molding requires a costly initial investment in the tool, but is more cost-effective in terms of total costs due to low unit prices for quantities of around 10,000 or more. This means that the manufacturing process only pays off for very large series.\u003C/p>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>3D printing has no initial tooling costs, but due to consistent production times, there is little scope for economies of scale in terms of quantity. Milling also incurs high unit costs, which quickly makes the process uneconomical for small and medium-sized series.\u003C/p>\u003Ch4>Foam / standard solutions\u003C/h4>\u003Cp>Foam solutions and standard solutions are cost-effective, but in many cases do not offer sufficient technical durability.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Design freedom & modification effort\u003C/span>\u003C/h3>\u003Cp>A manufacturing process that can respond flexibly to product changes, especially in the development phase, and does not make adjustments expensive or time-consuming reduces development risks. This allows updates and optimizations to be implemented without high additional costs.\u003C/p>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_15_1_406ba26690.webp\" alt=\"Plastic cover\">\u003C/figure>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>Deep drawing offers a high degree of flexibility and allows for adjustments, even for special requirements such as ESD or STANAG compliance.\u003C/p>\u003Ch4>Injection molding\u003C/h4>\u003Cp>Injection molding allows for design freedom, but changes to the tool often result in considerable effort and high adjustment costs.\u003C/p>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>Milling and 3D printing allow for changes. However, milling has geometric limitations, which reduces the scope for design. 3D printing allows for a great deal of creative freedom.\u003C/p>\u003Ch4>Foam / standard solutions\u003C/h4>\u003Cp>Foam and standard components offer little scope for customization and are limited to standard shapes.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Mechanical robustness\u003C/span>\u003C/h3>\u003Cp>Thermoformed parts such as housings or panels must be resilient in real-world use. An unsuitable process will result in components that deform, break, or are unsafe, which can lead to high follow-up costs in assembly and service.\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/behaeltnis_belastung_01_1_1_41d5d7d8e1.webp\" alt=\"Plastic container\">\u003C/figure>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>Thanks to adjustable wall thicknesses and the materials used, thermoforming offers high rigidity and excellent mechanical strength.\u003C/p>\u003Ch4>Injection molding\u003C/h4>\u003Cp>Injection-molded parts also achieve high strength and are mechanically equivalent to thermoformed parts in terms of robustness.\u003C/p>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>3D-printed components have significant limitations in terms of mechanical load capacity.\u003C/p>\u003Ch4>Foam / standard solutions\u003C/h4>\u003Cp>Foam solutions also have low mechanical load capacity and are therefore usually unsuitable for functional technical applications.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Material selection\u003C/span>\u003C/h3>\u003Cp>\u003Ca href=\"https://www.formary.de/en/materials\">Materials\u003C/a> determine both functionality and durability. Requirements such as \u003Ca href=\"https://www.formary.de/en/blog/esd-trays\">ESD protection\u003C/a>, UV resistance, temperature behavior, or chemical resistance are often crucial to a project. Processes with a limited selection of materials can severely restrict the area of application.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_16_1_5d8c0e1a7b.webp\" alt=\"Plastic flakes\">\u003C/figure>\u003Ch4>Plastic Thermoforming\u003C/h4>\u003Cp>Thermoforming allows for a wide range of materials, including specialized variants such as \u003Ca href=\"https://www.formary.de/en/products/esd-workpiece-carriers-for-electronics\">ESD-compatible\u003C/a> or flame-retardant materials, covering many technical requirements.\u003C/p>\u003Ch4>Injection molding\u003C/h4>\u003Cp>Injection molding offers a certain variety of materials, but is limited by process-specific requirements in the selection and combination of plastics.\u003C/p>\u003Ch4>Milling / 3D printing\u003C/h4>\u003Cp>The choice of materials for milling and 3D printing is highly dependent on the respective machine, meaning that not all engineering plastics can be used.\u003C/p>\u003Ch4>Foam / Standard solutions\u003C/h4>\u003Cp>Foams are difficult to specify and therefore only meet simple material requirements.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic manufacturing processes in tabular comparison:\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages\u003C/th>\u003Cth>\u003Cstrong>Plastic thermoforming\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Injection molding\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Milling / 3D printing\u003C/strong>\u003C/th>\u003Cth>\u003Cstrong>Foam / Standard solutions\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Time-to-Market\u003C/td>\u003Ctd>quickly achievable, depending on geometry & tooling\u003C/td>\u003Ctd>long tooling times (6–12 weeks)\u003C/td>\u003Ctd>quick for samples, but time-consuming for series production\u003C/td>\u003Ctd>immediately available, but lower precision\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Costs for small/medium series\u003C/td>\u003Ctd>very efficient, low tooling costs\u003C/td>\u003Ctd>high fixed costs, only worthwhile for large series\u003C/td>\u003Ctd>high unit costs\u003C/td>\u003Ctd>inexpensive, but short service life\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Design freedom & adaptability\u003C/td>\u003Ctd>high flexibility (also for ESD, STANAG, etc.)\u003C/td>\u003Ctd>high adaptation costs\u003C/td>\u003Ctd>geometrically limited (milling) / very free (3D printing)\u003C/td>\u003Ctd>hardly customizable\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Mechanical robustness\u003C/td>\u003Ctd>high rigidity due to wall thickness adjustment\u003C/td>\u003Ctd>high strength due to compacted plastic melt\u003C/td>\u003Ctd>limited with 3D printing; CNC robust\u003C/td>\u003Ctd>low stability\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Material selection (e.g., ESD, PC, STANAG)\u003C/td>\u003Ctd>wide selection, including specialized materials\u003C/td>\u003Ctd>limited by process-related requirements\u003C/td>\u003Ctd>depends on machine & process\u003C/td>\u003Ctd>hardly specifiable\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which plastic manufacturing process is right for my project?\u003C/span>\u003C/h2>\u003Cp>The choice of the appropriate process depends largely on the number of units, the type of component, and the cost requirements. A quick basis for decision-making:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Recommendation of the appropriate plastic process based on number of units\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Quantity\u003C/th>\u003Cth>Recommended plastic process\u003C/th>\u003Cth>\u003Cstrong>Why?\u003C/strong>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>1–20 pieces\u003C/td>\u003Ctd>3D printing or CNC milling\u003C/td>\u003Ctd>Maximum flexibility, no tooling costs, ideal for prototypes or functional samples.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>20–500 pieces\u003C/td>\u003Ctd>Thermoforming\u003C/td>\u003Ctd>Very low tooling costs, fast implementation, economical for small series.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>10,000 - 100,000 pieces\u003C/td>\u003Ctd>Thermoforming or injection molding (to be considered individually)\u003C/td>\u003Ctd>Thermoforming is most cost-effective for thin-walled, large components; injection molding is useful for high precision/detail requirements.\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>100,000+ pieces\u003C/td>\u003Ctd>typically injection molding (or thermoforming with appropriate tools)\u003C/td>\u003Ctd>High tooling costs are offset by minimal unit costs.\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">FAQ - Frequently asked questions about manufacturing processes for plastic parts\u003C/span>\u003C/h2>\u003Ch4>What plastic manufacturing processes are available?\u003C/h4>\u003Cp>The most important plastic manufacturing processes include thermoforming, injection molding, CNC milling, 3D printing, and foaming (e.g., foam solutions). The most suitable process depends on the number of units, geometry, material requirements, and budget.\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Which plastic manufacturing process is the most cost-effective?\u003C/span>\u003C/h4>\u003Cp>For small and medium series, \u003Cstrong>thermoforming\u003C/strong> is the most economical process. For large series, \u003Cstrong>injection molding\u003C/strong> remains unbeatable.\u003C/p>\u003Ch4>Which process is suitable for complex geometries?\u003C/h4>\u003Cul>\u003Cli>Filigree details → injection molding\u003C/li>\u003Cli>Complex free forms → 3D printing\u003C/li>\u003Cli>Large, thin-walled housings → thermoforming\u003C/li>\u003C/ul>\u003Ch4>Which is the most flexible process?\u003C/h4>\u003Cp>\u003Cstrong>Thermoforming:\u003C/strong> low tooling costs, quick changes, large components possible.\u003C/p>\u003Ch4>When is thermoforming more suitable than injection molding?\u003C/h4>\u003Cp>Thermoforming is more economical for small and medium-sized series, as tooling and adjustment costs are significantly lower and projects can be started more quickly.\u003C/p>\u003Ch4>Why is milling or 3D printing often unsuitable for series production?\u003C/h4>\u003Cp>Both processes require long machine times and result in correspondingly high unit costs, which quickly makes series production uneconomical.\u003C/p>\u003Ch4>How does design freedom affect manufacturability?\u003C/h4>\u003Cp>Greater design freedom facilitates adjustments but can lead to manufacturing risks. A \u003Ca href=\"https://www.formary.de/en/3d-services/dfm-analyse\">DFM analysis\u003C/a> ensures that geometries are suitable for deep drawing and can be implemented efficiently.\u003C/p>\u003Ch4>How do I find the right material for my component?\u003C/h4>\u003Cp>The \u003Ca href=\"https://www.formary.de/en/whitepaper-ebooks/materialguide-1\">Material Guide\u003C/a> provides a compact overview of available plastics, their properties, and their suitability for various applications.\u003C/p>\u003Ch4>Which industries benefit particularly from thermoforming?\u003C/h4>\u003Cp>Typical areas of application include \u003Ca href=\"https://www.formary.de/en/industries/mechanical-engineering\">mechanical engineering\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">medical technology\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/robotics\">robotics\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/electronics\">electronics\u003C/a>, and \u003Ca href=\"https://www.formary.de/en/industries/agriculture-horticulture\">horticulture\u003C/a>.\u003C/p>\u003Ch4>Are there sustainable alternatives?\u003C/h4>\u003Cp>Yes, with our \u003Ca href=\"https://www.formary.de/en/products/molded-fiber-packaging\">fiber casting\u003C/a> and \u003Ca href=\"https://www.formary.de/en/products/paper-pulp-injection-molded-packaging\">paper injection molding\u003C/a> solutions, we offer completely biodegradable products, or through the use of \u003Ca href=\"https://www.formary.de/en/blog/what-is-recyclate\">recyclates\u003C/a> and \u003Ca href=\"https://www.formary.de/en/blog/what-are-bioplastics\">bioplastics\u003C/a>.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Select the right manufacturing process for your project now\u003C/span>\u003C/h2>\u003Cp>Choosing the right process determines costs, speed, and technical performance. With formary, you not only receive high-quality products, but also support in selecting materials, surfaces, and the optimal process.\u003C/p>\u003Cp>On request, we can also check whether a combination of several plastic manufacturing processes makes sense—for example, \u003Ca href=\"https://www.formary.de/en/blog/rapid-prototyping-in-thermoforming\">prototyping\u003C/a> using 3D printing and subsequent series production using thermoforming. Start now with your inquiry via the \u003Ca href=\"https://www.formary.de/en/configurator\">formary configurator\u003C/a> and realize your next project quickly and efficiently.\u003C/p>","plastic-manufacturing-processes-compared",{"id":157,"documentId":907,"createdAt":908,"updatedAt":909,"publishedAt":910,"locale":10,"title":911,"introduction":912,"content":913,"slug":914},"p7xknhhak0ukuf45xqtqknjf","2026-01-13T15:51:49.205Z","2026-01-26T08:37:46.755Z","2026-01-26T08:37:47.237Z","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":916,"documentId":917,"createdAt":918,"updatedAt":919,"publishedAt":920,"locale":10,"title":921,"introduction":922,"content":923,"slug":924},462,"y6dpnh7b8vjzkuer2g0gjqbq","2026-01-13T15:51:52.410Z","2026-01-26T08:45:53.694Z","2026-01-26T08:45:54.310Z","Injection Molding vs. Plastic Thermoforming – Advantages, Disadvantages, Differences, and Similarities","In the world of plastic processing, there are various common manufacturing methods used to produce precise plastic components for industrial applications. We compare two of them: Injection Molding and Plastic Thermoforming.","\u003Cp>Both processes are suitable for various industries and applications, making it essential to understand their similarities, differences, advantages, disadvantages, and use cases. In this article, we compare injection molding and thermoforming to help you make the best decision for your specific application.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is Injection Molding?\u003C/span>\u003C/h2>\u003Cp>Injection molding is a widely used manufacturing process for producing plastic parts. It involves injecting molten plastic into a mold—hence the name. The plastic solidifies through hydraulic cooling, and once the mold opens, the finished part is ejected. But how exactly does the injection molding process work? Let's break it down.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does the Injection Molding Process Work?\u003C/span>\u003C/h2>\u003Col>\u003Cli>\u003Cstrong>Melting the Plastic:\u003C/strong> Plastic granules are heated until they become liquid. The mold, also known as the injection mold tool, is closed. This two-part mold forms the negative shape of the desired end product.\u003C/li>\u003Cli>\u003Cstrong>Injecting the Molten Plastic:\u003C/strong> The liquefied plastic is injected under high pressure into the closed mold, filling its cavities and taking its shape.\u003C/li>\u003Cli>\u003Cstrong>Cooling and Solidification:\u003C/strong> The injected plastic is cooled from the inside using water, causing it to solidify into a stable form.\u003C/li>\u003Cli>\u003Cstrong>Ejecting the Part:\u003C/strong> Once solidified, the mold opens, and the finished injection-molded part is removed.\u003C/li>\u003C/ol>\u003Ch3>\u003Cspan style=\"color:#005250;\">What Is Plastic Thermoforming?\u003C/span>\u003C/h3>\u003Cp>Plastic thermoforming, also known as vacuum forming, is a process in which thermoplastic sheets are heated, reshaped using forming machines, and cut into the desired shape by stamping or milling. This method enables the production of three-dimensional plastic parts with various shapes and sizes, tailored to specific applications.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How Does the Thermoforming Process Work?\u003C/span>\u003C/h2>\u003Col>\u003Cli>\u003Cstrong>Heating:\u003C/strong> The thermoplastic sheet is heated to its forming temperature, where it becomes elastic and moldable.\u003C/li>\u003Cli>\u003Cstrong>Forming:\u003C/strong> The softened sheet is stretched over a mold. It is secured in a frame and shaped using vacuum pressure or mechanical force. This process usually takes only a few seconds.\u003C/li>\u003Cli>\u003Cstrong>Cooling:\u003C/strong> The material cools upon contact with the mold, stabilizing its shape.\u003C/li>\u003Cli>\u003Cstrong>Trimming:\u003C/strong> Once cooled, excess material is removed using stamping or milling processes.\u003C/li>\u003C/ol>\u003Ch2>\u003Cspan style=\"color:#005250;\">\u003Cstrong>Injection Molding vs. Thermoforming: Key Differences\u003C/strong>\u003C/span>\u003C/h2>\u003Cp>In simple terms, \u003Cstrong>thermoforming is ideal for lower production volumes\u003C/strong>, while \u003Cstrong>injection molding is preferred for high-volume production\u003C/strong>. For example, plastic covers and casings are often produced in small to mid-sized quantities using thermoforming. In contrast, products like yogurt cups can be manufactured in the millions using this method.\u003C/p>\u003Cfigure class=\"table\">\u003Ctable>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Factor\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Injection Molding\u003C/strong>\u003C/td>\u003Ctd>\u003Cstrong>Thermoforming\u003C/strong>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Tooling Costs\u003C/strong>\u003C/td>\u003Ctd>High (starting at €20,000)\u003C/td>\u003Ctd>Low (€500 – €10,000)\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Production Time\u003C/strong>\u003C/td>\u003Ctd>10+ weeks for tooling\u003C/td>\u003Ctd>1–2 weeks for tooling\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Tolerances\u003C/strong>\u003C/td>\u003Ctd>±0.1 mm to ±0.025 mm\u003C/td>\u003Ctd>±1 mm\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Production Volume\u003C/strong>\u003C/td>\u003Ctd>High (thousands to millions)\u003C/td>\u003Ctd>Low to mid-volume (10 – 100,000+)\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Cp>Compared to injection molding, the initial investment in the tool is low. This makes the deep drawing process a sensible option even for \u003Cstrong>small quantities\u003C/strong>. The low tooling costs are due in part to the simpler design of the mold, which is primarily a result of the single-sided tool design.\u003C/p>\u003Cp>Unlike injection molding, no cavity (two-part tool) is required for the forming process. Depending on the design, material, number of uses, size, and structure, thermoforming tools cost between €500 and €10,000, but can be significantly higher for large parts or multi-use tools. For injection molding tools, the costs are normally €20,000 and up, even for smaller parts.\u003C/p>\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>ℹ️ \u003Cb>Important to note:\u003C/b> Once the deep-drawing tool has been created from series material, such as aluminum, it can be scaled up to very high quantities, which can easily reach six figures without reworking. \u003C/p>\n\u003C/div>\u003C/div>\u003Cp>While standard injection molding tools require at least 10 weeks to manufacture, thermoforming tools can be milled by the toolmaker in as little as \u003Cstrong>1-2 weeks\u003C/strong> in the best case scenario.\u003C/p>\u003Cp>Deep-drawn parts are designed for the majority of industrial and packaging applications with a tolerance of +/- ~1 mm. This corresponds to the tolerance range according to \u003Cstrong>ISO 2768-c\u003C/strong> for the 120 to 400 mm length dimensions commonly used in this product area. In injection molding, typical tolerances are +/-0.1 mm and very tight tolerances are +/- 0.025 mm, which is tighter than in thermoforming.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of injection molding\u003C/span>\u003C/h2>\u003Cp>Injection molding makes it possible to produce a \u003Cstrong>high number of\u003C/strong> precise plastic parts. Continuous consistency and repeatability are crucial, especially when producing large quantities of plastic components, and these are precisely the aspects that the injection molding process guarantees. Despite the many advantages offered by the injection molding process, there are also some potential disadvantages to consider.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Overview of the possibilities and limitations of the injection molding process\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of injection molding\u003C/span> \u003C/p>\u003C/th>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of injection molding\u003C/span> \u003C/p>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Low unit costs for mass production\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">High tooling costs \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">High precision and reproducibility \u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Comparatively high wear on tools \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Suitable for complex shapes and contours such as hooks, combs, and ribs\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Thin-walled parts often more expensive than deep drawing \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">High surface quality\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">High energy consumption \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Injection molded parts do not require reworking\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Design changes are expensive \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Process can be fully automated\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Long lead times \u003C/p>\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of plastic thermoforming\u003C/span>\u003C/h2>\u003Cp>Thermoforming proves to be unbeatable, especially in the production of \u003Cstrong>medium-sized series \u003C/strong>with time constraints. Thermoforming plastic offers numerous advantages for the economical production of aesthetically appealing plastic products. Low tooling costs, short lead times, a comprehensive selection of materials, high reproducibility, and a first-class appearance characterize the thermoforming process. These features enable flexible application in various industries where thermoformed plastic parts are in demand.\u003C/p>\u003Cp>However, it is important to note that, unlike injection molding, the tool in the thermoforming process only has contact with the material on one side, which entails certain geometric restrictions. More on this in the Design Guide.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Overview of the possibilities and limitations of plastic thermoforming\u003C/span>\u003C/h2>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Advantages of plastic thermoforming\u003C/span>\u003C/p>\u003C/th>\u003Cth>\u003Cp style=\"text-align:center;\">\u003Cspan style=\"color:hsl(0,0%,0%);\">Disadvantages of plastic thermoforming\u003C/span> \u003C/p>\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Low investment costs for tools \u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Tool adjustments can be expensive \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Cost-effective production\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Slightly slower manufacturing process than injection molding \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Worthwhile even for small quantities \u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Complex shapes with very thin walls are limited \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Optimal options for post-processing\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Potential difficulty in achieving uniform material thicknesses in complex shapes \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Post-industrial recycling possible for simple cycles \u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">One-sided material contact \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Unrivaled for thin-walled parts\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">More complex geometries from the injection molding sector cannot be produced \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Short lead times\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Semi-finished products more expensive than with injection molding \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">Large selection of materials\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Cutting and punching costs \u003C/p>\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cp style=\"text-align:center;\">All sizes and shapes possible (large parts)\u003C/p>\u003C/td>\u003Ctd>\u003Cp style=\"text-align:center;\">Potential sources of error in semi-finished product manufacturing due to frozen stresses in the material during extrusion\u003C/p>\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Similarities between plastic thermoforming and injection molding\u003C/span>\u003C/h2>\u003Cp>Plastic products offer a number of advantages. These include:\u003C/p>\u003Cul>\u003Cli>Low weight\u003C/li>\u003Cli>Durability\u003C/li>\u003Cli>Corrosion resistance\u003C/li>\u003Cli>Electrical insulation\u003C/li>\u003C/ul>\u003Cp>The lower density of plastics compared to metals is not only advantageous in vehicles. The ability to withstand electrical voltages with ESD trays contributes significantly to the operational safety of all types of equipment. In addition, many thermoplastics are corrosion-resistant and durable, which contributes to the long-term usability of the products.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Areas of application for injection molding and plastic thermoforming\u003C/span>\u003C/h2>\u003Cp>Some products can be both injection molded and deep drawn with adapted geometries. Therefore, there is a number of overlaps between plastic injection molding and plastic thermoforming. The choice between thermoforming and injection molding depends on the specific requirements of the product, the materials, the number of pieces, and the costs.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typical industries and applications in which injection molding and thermoforming are used\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/en/products/thermoformed-plastic-packaging\">\u003Cstrong>Packaging\u003C/strong>\u003C/a>\u003Cstrong>:\u003C/strong> Plastic deep drawing and injection molding are often used for the manufacture of packaging, especially for plastic containers, trays, and enclosures. Closures for containers, such as hinged lids, can be both injection molded and thermoformed.\u003C/li>\u003Cli>\u003Cstrong>Automotive:\u003C/strong> Both injection molding and plastic thermoforming are used to manufacture parts for the automotive industry, such as interior trim, door panels, dashboards, and covers. The choice of process depends on the design and cost requirements.\u003C/li>\u003Cli>\u003Cstrong>Medical & pharmaceutical:\u003C/strong> Plastic containers for storing laboratory samples, such as blood samples or tissue samples, can be manufactured using both processes. An increasingly important area is medical technology housings for medical devices such as surgical lights, laser systems, and MRIs. Thanks to the development of modern machines and tools, plastic deep-drawn parts are replacing injection molding and alternative processes in this area due to their multiple advantages.\u003C/li>\u003Cli>\u003Cstrong>Electronics & semiconductor technology:\u003C/strong> Some plastic housings for electronic devices such as remote controls or small electronic gadgets can be produced using both processes.\u003C/li>\u003Cli>\u003Cstrong>Consumer goods:\u003C/strong> Plastic plates, bowls, and cups are manufactured using both injection molding and thermoforming, depending on the manufacturing costs and the desired geometries.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">The injection molding process is worthwhile here\u003Cstrong>:\u003C/strong>\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Delicate small parts\u003C/strong>: Detailed small parts in all industries, such as lipstick cases, figures for the toy industry, screws, nuts, clips, switches, connectors, etc., are often manufactured using injection molding because they have complex geometries and are produced in large quantities.\u003C/li>\u003Cli>\u003Cstrong>Automotive components\u003C/strong>: Many parts in the automotive industry, such as switch covers, trim panels, buttons, and brackets, are produced using injection molding because they often have complex shapes and require high precision.\u003C/li>\u003Cli>\u003Cstrong>Electrical enclosures\u003C/strong>: Plastic enclosures for electronic devices such as mobile phones, laptops, televisions, and cameras are often produced by injection molding to ensure the desired shape and precision.\u003C/li>\u003Cli>\u003Cstrong>Medical devices\u003C/strong>: Many components of medical devices, such as infusion pump housings or parts of diagnostic devices, are manufactured using injection molding to meet hygiene requirements and precision standards.\u003C/li>\u003C/ul>\u003Ch3>\u003Cspan style=\"color:#005250;\">The deep drawing process is particularly useful here:\u003C/span>\u003C/h3>\u003Cul>\u003Cli>\u003Cstrong>Deep-drawn trays\u003C/strong>: Trays and swing-top packaging are ideal for plastic thermoforming, are highly versatile and require less investment in tools.\u003C/li>\u003Cli>\u003Cstrong>Blister packaging\u003C/strong>: Plastic blisters and inlays are often used for packaging medicines, food and other consumer goods because they are thin-walled, are required in large quantities and tooling costs can be kept low.\u003C/li>\u003Cli>\u003Cstrong>Cladding for automotive and new mobility\u003C/strong>: Some thin-walled parts in vehicles, such as interior trim and storage compartments, are manufactured using plastic thermoforming to save weight and keep costs low.\u003C/li>\u003Cli>\u003Cstrong>Covers and housings:\u003C/strong> The thermoforming process is particularly suitable for machines, technical devices, and robotics, especially for smaller quantities or prototype production.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Plastic thermoforming or injection molding? - Conclusion and recommendations\u003C/span>\u003C/h2>\u003Cp>The choice between injection molding and thermoforming depends on various factors. Tooling costs, geometries, quantities, delivery times—all these aspects must be weighed up when deciding between the two processes.\u003C/p>\u003Cp>For comparatively low investment costs, production quantities of 5-10,000, and short delivery times, plastic thermoforming is the optimal solution. In any case, a precise analysis of the requirements is important in order to make the best possible decision.\u003C/p>\u003Cp>Do you have questions about deep drawing? Feel free to contact us and we will help you with your project planning in thermoforming.\u003C/p>","injection-molding-vs-thermoforming",{"id":926,"documentId":927,"createdAt":928,"updatedAt":929,"publishedAt":930,"locale":10,"title":931,"introduction":932,"content":933,"slug":934},464,"z04clvcm39kx033cnl5xscms","2026-01-13T15:51:52.763Z","2026-01-26T08:46:43.509Z","2026-01-26T08:46:43.869Z","Thermoforming Tool for Plastic Thermoformed Parts: Structure, Types, and Manufacturing","Plastic thermoforming is a process in which a plastic sheet or film is heated and shaped over a mold to create various three-dimensional objects. A crucial element in the thermoforming process is the tooling used to achieve the desired shape.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Thermoforming Tools for Plastic Thermoformed Parts – Key Facts at a Glance\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Thermoforming tools are indispensable in the thermoforming process, as they precisely shape plastic sheets and films, cool them, and define the surface quality. Each tool is individually designed for the specific product.\u003C/li>\u003Cli>Aluminum is the standard material for durable production tools, while Ureol, 3D printing, and wood are mainly used for prototypes or small quantities to reduce costs and development time.\u003C/li>\u003Cli>Negative and positive thermoforming tools differ in shaping and level of detail: Negative molds allow smooth surfaces and good wall thickness distribution, while positive molds are more cost-effective but less detailed.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Is a Thermoforming Tool?\u003C/span>\u003C/h2>\u003Cp>A thermoforming tool is a specialized tool used in the single-sheet or \u003Ca href=\"https://www.formary.de/en/blog/twin-sheet-process\">twin-sheet\u003C/a> process to shape thermoplastic sheets or films, which are produced through \u003Ca href=\"https://www.formary.de/en/blog/plastic-extrusion\">plastic extrusion, \u003C/a>into molded plastic components. The material is softened by heating and then formed into a shape using \u003Ca href=\"https://www.formary.de/en/blog/vacuum-forming\">vacuum forming\u003C/a> or \u003Ca href=\"https://www.formary.de/en/blog/pneumatic-forming\">pressure forming.\u003C/a>\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:36.19%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Isometrische_Darstellung_eines_Tiefziehwerkzeugs_3b8e047f20.png\" alt=\"Isometrische Darstellung eines Tiefziehwerkzeugs\">\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Why Is a Thermoforming Tool Necessary?\u003C/span>\u003C/h2>\u003Cp>Thermoforming tools are essential for the deep-drawing process. Without a precise thermoforming tool, plastic cannot be shaped into the desired form. Each tool is custom-made for every product development, designed to meet specific requirements, and then installed in the machine for production—a process known as machine setup.\u003C/p>\u003Cp>Since thermoforming tools are tailored for each product, they are typically unique and adapted to the specific project’s production volume, quality standards, and tolerances.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Functions of Thermoforming Tools\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:8.04%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Funktionsweise_von_Tiefziehwerkzeugen_f6847ae73d.png\" alt=\"Funktionsweise von Tiefziehwerkzeugen\">\u003Cfigcaption>Thermoforming Process\u003C/figcaption>\u003C/figure>\u003Cp>Thermoforming tools serve multiple functions in the manufacturing process:\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>Shaping\u003C/strong> – The tool gives the heated plastic its final shape.\u003C/li>\u003Cli>\u003Cstrong>Cooling\u003C/strong> – It facilitates cooling to stabilize the form.\u003C/li>\u003Cli>\u003Cstrong>Surface Finish\u003C/strong> – The tool influences the texture and quality of the finished product’s surface.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Do You Need a New Thermoforming Tool for Every Product?\u003C/span>\u003C/h2>\u003Cp>Yes, since thermoforming tools are custom-made for each product. However, once a tool is created, it can be used for \u003Cstrong>tens or even hundreds of thousands\u003C/strong> of production cycles, especially if made from \u003Cstrong>aluminum\u003C/strong> and properly maintained.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Single-Cavity vs. Multi-Cavity Tools\u003C/span>\u003C/h3>\u003Cp>A \u003Cstrong>single-cavity tool\u003C/strong> forms one part per production cycle, suitable for small batch production. A \u003Cstrong>multi-cavity tool\u003C/strong> forms multiple identical parts in a single cycle, reducing production time and per-unit cost for high-volume manufacturing.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">What Happens to Thermoforming Tools After Use?\u003C/span>\u003C/h3>\u003Cp>After production, the tool is removed, cleaned, and inspected for any necessary repairs before being stored for future use.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Materials Used in Thermoforming Tools\u003C/span>\u003C/h2>\u003Ch3>\u003Cspan style=\"color:#005250;\">Aluminum (Industry Standard for Serial Production)\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Most commonly used due to its high precision, durability, and lightweight properties.\u003C/li>\u003Cli>Water-cooled aluminum tools allow for fast cooling times, making them ideal for high-speed production.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:19.31%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehwerkzeug_aus_Aluminium_14e5426ea7.png\" alt=\"Tiefziehwerkzeug aus Aluminium\">\u003Cfigcaption>Aluminum deep drawing tool\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Ureol (Polyurethane Foam)\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Used for prototypes due to its low cost and easy machining.\u003C/li>\u003Cli>Not as durable as aluminum and suitable only for limited production runs.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:19.83%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehwerkzeug_aus_Ureol_774b94170a.png\" alt=\"Tiefziehwerkzeug aus Ureol\">\u003Cfigcaption>Deep-drawing tool made of ureol\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">3D-Printed Plastic\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Fast and cost-effective for prototyping and testing.\u003C/li>\u003Cli>Only capable of producing a small number of samples due to heat resistance limitations.\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:18.67%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/3_D_gedrucktes_Tiefziehwerkzeug_211216daea.png\" alt=\"3D-gedrucktes Tiefziehwerkzeug\">\u003Cfigcaption>3D-printed thermoforming tool\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Wood\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Rarely used, as it wears out quickly and lacks precision.\u003C/li>\u003Cli>Can be utilized for simple forming stamps or pre-stretching components.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Construction of deep-drawing tools\u003C/span>\u003C/h2>\u003Cp>The deep-drawing tool consists of several components, including the mold itself, cooling channels that ensure uniform cooling, and holding devices that keep the plastic in position during the process. These elements work together during deep drawing to ensure precise and efficient shaping.\u003C/p>\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>\u003C/p>\u003Ch4>ℹ️ The mandatory tool set for deep drawing tools\u003C/h4>\nThe simplest tool set always consists of a base, a segment carrier plate and a forming tool mounted on it.\n\u003Cul>\n\u003Cli>\u003Cb>Forming tool:\u003C/b> The forming body of the deep drawing tool.\n\u003C/li>\u003Cli>\u003Cb>Segment carrier plate:\u003C/b> The carrier plate for the forming tool.\n\u003C/li>\u003Cli>\u003Cb>Base:\u003C/b> The segment carrier plate with the forming tool is screwed onto this. The base is the interface to the machine. Each machine requires an individual base, which is usually the same for certain models depending on the manufacturer.\n\u003C/li>\u003C/ul>\n\u003Cp>\u003C/p>\n\u003C/div>\u003C/div>\u003Cp>The aim is to keep the deep-drawing tool within a constant temperature range in order to achieve a uniform result.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:23.89%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Querschnitt_eines_Tiefziehwerkzeugs_0f53121f0b.png\" alt=\"Querschnitt eines Tiefziehwerkzeugs\">\u003C/figure>\u003Cp>The illustration shows a cross-section of the entire structure of a tool, including some standard tool components. Shown here are the machine base (8) and the carrier plate (7 in petrol), on which the positive mold (13) is mounted, which works with compressed air (1) and vacuum (9). The material (5), i.e. the plastic roll or sheet, is marked in black here.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Additional components of deep-drawing tools\u003C/span>\u003C/h3>\u003Cp>In addition to the mandatory tool set (which of course also varies from machine to machine), further tool components can be created. Each of these components fulfills a specific purpose. When designing the deep-drawing tool, a decision is made as to whether and in what form separate components need to be created.\u003C/p>\u003Cp>This depends primarily on the optical and mechanical requirements of the deep-drawn part. In some cases, additional components are used “only” to optimize the result, while in others, additional components are essential for a functional part. It is important to consider the tool options available.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Pre-stretching punch\u003C/span>\u003C/h4>\u003Cp>The pre-stretching punch, also known as the \u003Cstrong>upper punch\u003C/strong>, is used to pre-stretch and shape the material in order to achieve better forming sharpness. Pre-stretching distributes the material more evenly, which allows for deep, complex shapes and the use of thinner starting thicknesses.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:23.37%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Querschnitt_eines_Oberstempelwerkzeugs_afc194436a.png\" alt=\"Querschnitt eines Oberstempelwerkzeugs\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Spanning frame components\u003C/span>\u003C/h4>\u003Cp>Spanning frames clamp the material during \u003Ca href=\"https://www.formary.de/plattenfertigung\">deep drawing from the plastic sheet\u003C/a> during processing to hold it in place during forming.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:23.37%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Spannrahmenkomponenten_bei_Tiefziehwerkzeugen_6cf9bc41da.png\" alt=\"Spannrahmenkomponenten bei Tiefziehwerkzeugen\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ejectors\u003C/span>\u003C/h4>\u003Cp>Automated ejectors support \u003Cstrong>demolding.\u003C/strong> These are used to achieve faster cycle times and to automatically feed the deep-drawn parts to a stacking unit.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:19.61%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Ausstosser_von_Tiefziehwerkzeugen_3b5d1e922d.png\" alt=\"Ausstoßer von Tiefziehwerkzeugen\">\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Stacking stations\u003C/span>\u003C/h4>\u003Cp>After the deep-drawn part has been removed from the deep-drawing tool, stacking stations can automatically stack the parts into stacking units. This facilitates the removal and packaging process from the machine.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">What is the difference between positive and negative tools in plastic deep drawing?\u003C/span>\u003C/h2>\u003Cp>Basically, during the forming process, the semi-finished product is stretched into the desired shape by placing the heated material in a rubber-elastic form on the tool and allowing it to cool.\u003C/p>\u003Cp>The forming process can be divided into two types: \u003Cstrong>positive and negative molding.\u003C/strong> The choice of process depends primarily on which side of the deep-drawn part must be dimensionally accurate and whether the required stability must be maintained at the bottom or at the edge of the plastic deep-drawn part.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Negative tool\u003C/span>\u003C/h3>\u003Cp>In negative molding, the semi-finished product is pressed into the \u003Cstrong>concave mold cavity\u003C/strong>. This can be done using vacuum or additional compressed air. To ensure uniform wall thicknesses, an upper punch made of an insulating material can also be used, which pushes material into thinning areas of the deep-drawn part during molding.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:17.26%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Negativ_Tiefziehwerkzeug_21b50ae2bf.png\" alt=\"Negativ-Tiefziehwerkzeug\">\u003Cfigcaption>negative deep-drawing tool\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of negative deep-drawing tools\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of negative deep-drawing tools\u003C/th>\u003Cth>Disadvantages of negative deep-drawing tools\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Good wall thickness distribution\u003C/td>\u003Ctd>Increased material costs\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Smooth, flawless surface\u003C/td>\u003Ctd>Increased risk of material cracks and wrinkling\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Good demoldability \u003C/td>\u003Ctd>Top punch usually required\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Positive tool\u003C/span>\u003C/h3>\u003Cp>In positive molding, the semi-finished product is pulled over a \u003Cstrong>convex elevation\u003C/strong>. To avoid thin spots at the edges, the material is often pre-blown with compressed air from below.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.99%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Positiv_Tiefziehwerkzeug_95cf66e92e.png\" alt=\"Positiv-Tiefziehwerkzeug\">\u003Cfigcaption>Positiv-Tiefziehwerkzeug\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Advantages and disadvantages of positive deep-drawing tools\u003C/span>\u003C/h3>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Advantages of positive deep-drawing tools\u003C/th>\u003Cth>Disadvantages of positive deep-drawing tools\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Simple and cost-effective production\u003C/td>\u003Ctd>Lower level of detail\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Improved wall thickness distribution compared to negative tools without upper punch \u003C/td>\u003Ctd>Limited surface quality, the outside of the part may be less smooth, which affects aesthetics\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Good surfaces on the outside \u003C/td>\u003Ctd>Difficult demolding with complex geometries\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Manufacture of deep-drawing tools\u003C/span>\u003C/h2>\u003Cp>Deep-drawing tools for plastics processing are manufactured in the following steps:\u003C/p>\u003Col>\u003Cli>Design\u003C/li>\u003Cli>CNC milling\u003C/li>\u003Cli>Manual re-milling\u003C/li>\u003C/ol>\u003Cp>More on this in the following sections.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Designing a deep-drawing tool\u003C/span>\u003C/h3>\u003Cp>The first step in the manufacture of a deep-drawing tool is the design, which is usually done using CAD data that shows the deep-drawing tool sketch. The exact specifications and designs of the tool are developed to ensure that the thermoforming tool meets the requirements. Read more about this \u003Ca href=\"https://www.formary.de/en/blog/construction-data-in-thermoforming\">here\u003C/a>.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">CNC milling\u003C/span>\u003C/h3>\u003Cp>After design, the deep drawing tool is machined from the selected material using 5-axis \u003Ca href=\"https://www.formary.de/en/post-processing-methods/trennen/cnc-milling\">CNC milling.\u003C/a> CNC milling offers high precision, which is essential for the manufacture of high-quality tools.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:14.25%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/CNC_Fraesen_von_Tiefziehwerkzeugen_11f4f4139c.jpg\" alt=\"CNC-Fräsen von Tiefziehwerkzeugen\">\u003C/figure>\u003Ch3>Manual re-milling\u003C/h3>\u003Cp>CNC milling is often followed by manual reworking to optimize fine details, create very precise vacuum holes, and improve the surface quality. These reworking steps are essential to ensure that the deep-drawing tool meets the high requirements of production.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Frequently Asked Questions About Thermoforming Tools\u003C/span>\u003C/h2>\u003Ch4>What is the main purpose of a thermoforming tool?\u003C/h4>\u003Cp>It shapes heated plastic, ensures uniform wall thickness, and influences surface quality.\u003C/p>\u003Ch4>What materials are used for thermoforming tools?\u003C/h4>\u003Cp>Aluminum for series production, Ureol for prototypes, 3D-printed plastic for small quantities, and wood for simple or special applications.\u003C/p>\u003Ch4>What is the difference between male and female thermoforming tools?\u003C/h4>\u003Cp>Female tools use concave molds for better wall thickness distribution; male tools use convex shapes and are simpler but less detailed.\u003C/p>\u003Ch4>When does a multi-cavity tool make sense?\u003C/h4>\u003Cp>For high production volumes to reduce cycle times and unit costs.\u003C/p>\u003Ch4>How is a thermoforming tool manufactured?\u003C/h4>\u003Cp>Via CAD design, CNC milling, and manual finishing for precision and surface quality.\u003C/p>\u003Ch4>Is tool transfer to another supplier possible?\u003C/h4>\u003Cp>Yes, a \u003Ca href=\"https://www.formary.de/en/blog/tool-transfer-in-thermoforming\">tool transfer\u003C/a> is possible, if the tool is the customer’s property, it can be transferred to another thermoforming supplier without issues.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Deep-drawing tools in plastic thermoforming – a conclusion\u003C/span>\u003C/h2>\u003Cp>Deep-drawing tools are essential for the production of plastic deep-drawn parts. When designing the tool, it is important to consider which additional components are required to meet the requirements of the deep-drawn part in order to meet the quality standards. The optimal deep-drawn part is therefore designed to suit the material, process, and tool.\u003C/p>\u003Cp>Would you like to get started with your deep drawing project and have further questions about deep drawing tools? Then read our design guide, which answers all your questions about thermoforming.\u003C/p>","tools-for-thermoformed-plastic-parts",{"id":936,"documentId":937,"createdAt":938,"updatedAt":938,"publishedAt":939,"locale":10,"title":940,"introduction":941,"content":942,"slug":943},471,"qxno01sf2rt8pqai32egt8vd","2026-01-26T14:12:29.136Z","2026-01-26T14:12:29.168Z","Tool Transfer in Thermoforming: A Guide for Existing Thermoformed Tools","Tool transfer in thermoforming makes it possible to continue using existing tools and to keep producing components without unnecessary costs or delays. In this article, you will learn about the benefits this offers, which information is required, and how formary efficiently supports the entire process.","\u003Ch2>Tool Transfer in Plastic Thermoforming – Key Facts in Brief\u003C/h2>\u003Cul>\u003Cli>A \u003Cstrong>tool transfer\u003C/strong> allows existing thermoforming tools to be reused without the need to manufacture new tooling.\u003C/li>\u003Cli>Companies \u003Cstrong>save \u003C/strong>costs and time while reducing project risks and waste.\u003C/li>\u003Cli>For a smooth transfer, key \u003Cstrong>technical data \u003C/strong>must be available and clarified in advance.\u003C/li>\u003Cli>formary handles the\u003Cstrong> technical assessment \u003C/strong>and ensures efficient integration into the serial production process.\u003C/li>\u003C/ul>\u003Chr>\u003Ch3>What Does Tool Transfer in Thermoforming Mean?\u003C/h3>\u003Cp>Tool transfer, often also referred to as tool relocation, describes the transfer of an existing \u003Ca href=\"https://www.formary.de/en/blog/tools-for-thermoformed-plastic-parts\">thermoforming tool \u003C/a>to a new manufacturer in order to continue production there without creating a new tool.\u003C/p>\u003Cp>A prerequisite for a tool transfer to a new thermoforming supplier is that the tool is owned by the customer. This is typically the case if the tooling costs were listed separately in the original quotation and not allocated proportionally to part prices. In this situation, the tool belongs to the customer and can be withdrawn from the current manufacturer and relocated to another producer at any time.\u003C/p>\u003Cp>\u003Cstrong>The aim of tool transfer:\u003C/strong> to continue using existing tools efficiently and to maintain production without interruption.\u003C/p>\u003Ch3>When Does a Tool Transfer in Thermoforming Make Sense?\u003C/h3>\u003Cp>Relocating thermoforming tools is particularly beneficial when an existing thermoforming tool is still fully functional and capable of production. By continuing to use an existing tool instead of building a completely new one, companies can keep using their thermoformed tools economically, even if contract manufacturing with the current supplier is no longer desired.\u003C/p>\u003Cp>Once a tool has been manufactured, it can typically be used for production over a very long service life. When aluminum tools are used and regular maintenance is carried out, production volumes of tens or even hundreds of thousands of cycles are common.\u003C/p>\u003Ch2>Why Are Thermoforming Tools Typically Transferred?\u003C/h2>\u003Cp>In industrial practice, the relocation of existing thermoforming tools can be a strategically important step. Companies sourcing plastic thermoformed parts usually relocate tools to ensure production continuity, control costs, and minimize risks.\u003C/p>\u003Cp>\u003Cstrong>Typical reasons for tool relocation include:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>\u003Cstrong>(Impending) insolvency or business closure of the current supplier\u003C/strong>\u003Cbr>To avoid production stoppages, tools are transferred early to an alternative manufacturer.\u003C/li>\u003Cli>\u003Cstrong>Quality issues within the existing supply chain\u003C/strong>\u003Cbr>Repeated deviations in dimensional accuracy, surface quality, or material processing make a change of supplier necessary.\u003C/li>\u003Cli>\u003Cstrong>Increasing cost pressure\u003C/strong>\u003Cbr>Changes in pricing structures, energy costs, or labor costs may require a more economical production setup.\u003C/li>\u003Cli>\u003Cstrong>Risk management and supply chain security\u003C/strong>\u003Cbr>Tool relocations are a proven means of reducing dependencies and increasing supply reliability.\u003C/li>\u003Cli>\u003Cstrong>Tool damage or limited production capability\u003C/strong>\u003Cbr>When maintenance, repairs, or modifications can no longer be carried out reliably by the current supplier.\u003C/li>\u003Cli>\u003Cstrong>Prevention of production downtime\u003C/strong>\u003Cbr>Early relocation helps prevent unplanned stoppages in series products with long life cycles.\u003C/li>\u003C/ul>\u003Ch2>Advantages of taking over existing thermoforming tools:\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Cost efficiency:\u003C/strong> Avoiding new tool costs leads to significant cost savings.\u003C/li>\u003Cli>\u003Cstrong>Fast start of series production:\u003C/strong> Since the tool already exists and has been tested, sampling, \u003Ca href=\"https://www.formary.de/en/blog/rapid-prototyping-in-thermoforming\">prototyping\u003C/a>, and production can begin much earlier.\u003C/li>\u003Cli>\u003Cstrong>High process reliability:\u003C/strong> Geometries and material behavior have already been validated, ensuring functionality and requiring only minimal adjustments.\u003C/li>\u003Cli>\u003Cstrong>Sustainability:\u003C/strong> The service life of the tool is extended and unnecessary new construction is avoided.\u003C/li>\u003C/ul>\u003Ch2>Guide: How Tool Transfer Works with formary\u003C/h2>\u003Cp>To ensure that a thermoforming tool can be seamlessly transferred to a new manufacturer, all technical details must be clarified in advance. formary reviews this information to ensure compatibility and a fast start to serial production.\u003C/p>\u003Cp>The following questions should therefore be clarified upfront:\u003C/p>\u003Ch3>1. CAD Data\u003C/h3>\u003Cul>\u003Cli>Are CAD data for the tool available?\u003C/li>\u003Cli>Can 2D or 3D files be provided?\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:474/384;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_18_1_0bd8cce6ce.webp\" alt=\"Tiefziehteil CAD-Daten\" width=\"474\" height=\"384\">\u003C/figure>\u003Ch3>2. Photos & Visual Inspection\u003C/h3>\u003Cul>\u003Cli>Are images of the tools available?\u003C/li>\u003Cli>Are the vacuum ports visible?\u003C/li>\u003Cli>What is the general condition?\u003C/li>\u003C/ul>\u003Cp>Photos provide a quick indication of whether the tool, frame, and surfaces are intact.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1280/720;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehwerkzeug_aus_Aluminium_1_093e9a4690.webp\" alt=\"Tiefziehwerkzeug aus Aluminium\" width=\"1280\" height=\"720\">\u003C/figure>\u003Ch3>3. Dimensions\u003C/h3>\u003Cul>\u003Cli>What is the overall size of the tool?\u003C/li>\u003Cli>What specific forming dimensions are involved?\u003C/li>\u003C/ul>\u003Cp>These details affect machine compatibility and clamping options.\u003C/p>\u003Ch3>4. Substructures & Frames\u003C/h3>\u003Cul>\u003Cli>Are substructures available?\u003C/li>\u003Cli>Will these be provided?\u003C/li>\u003Cli>Is a suitable frame available?\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:849/811;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_19_1_c600d57323.webp\" alt=\"Spannrahmen Tiefziehteil\" width=\"849\" height=\"811\">\u003C/figure>\u003Cul>\u003Cli>Is a top plug required – and if so, is it included?\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:953/853;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_20_1_a3b9e0d2af.webp\" alt=\"Oberstempel Tiefziehen\" width=\"953\" height=\"853\">\u003C/figure>\u003Cp>All of these elements are important to ensure that the tool can be correctly installed on the target machine.\u003C/p>\u003Ch3>5. Base Plate\u003C/h3>\u003Cul>\u003Cli>What are the dimensions of the base plate on which thermoforming has previously been carried out?\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:784/556;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_21_1_8484270a9f.webp\" alt=\"Segmentträgerplatte\" width=\"784\" height=\"556\">\u003C/figure>\u003Ch3>6. Cooling\u003C/h3>\u003Cul>\u003Cli>What type of cooling does the tool have?\u003C/li>\u003C/ul>\u003Cp>This is a relevant factor for cycle times and repeatability (see blog article: \u003Ca href=\"https://www.formary.de/en/blog/tools-for-thermoformed-plastic-parts\">Thermoforming tools for plastic thermoformed parts\u003C/a>).\u003C/p>\u003Ch3>7. Number of Cavities\u003C/h3>\u003Cul>\u003Cli>How many cavities does the tool have?\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\u003Cb>Single-Cavity Tooling:\u003C/b> One part per cycle, ideal for small production volumes and low tooling costs.\n\u003Cbr>\n\u003Cb>Multi-Cavity Tooling: \u003C/b> Multiple identical parts per cycle, with higher tooling costs but significantly lower unit costs in series production.\u003C/p>\n \u003C/div>\u003C/div>\u003Ch3>8. Previously Used Machine\u003C/h3>\u003Cul>\u003Cli>On which machine (manufacturer, model) has the tool been used so far?\u003C/li>\u003C/ul>\u003Cp>This information helps facilitate the compatibility assessment. formary operates the following machines in its portfolio:\u003C/p>\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/en/roll-production\">\u003Cstrong>Roll-Fed Machines:\u003C/strong>\u003C/a>\u003Cul>\u003Cli>Illig RV\u003C/li>\u003Cli>Illig IC-RD\u003C/li>\u003Cli>Illig IC-RDK\u003C/li>\u003Cli>Illig IC-RDKP\u003C/li>\u003Cli>Kiefel KMD\u003C/li>\u003Cli>Kiefel KMV\u003C/li>\u003Cli>Kiefel KTR\u003C/li>\u003Cli>Hamer TFP\u003C/li>\u003Cli>Gabler Focus\u003C/li>\u003C/ul>\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/en/sheet-production\">\u003Cstrong>Sheet-Fed Machines:\u003C/strong>\u003C/a>\u003Cul>\u003Cli>Geiss T10\u003C/li>\u003Cli>Geiss U8\u003C/li>\u003Cli>Illig UA\u003C/li>\u003Cli>Berg M7\u003C/li>\u003C/ul>\u003C/li>\u003C/ul>\u003Ch3>9. Trimming and Post-Processing Tools\u003C/h3>\u003Cp>Depending on the downstream processing, the following documents or fixtures are required:\u003C/p>\u003Ch4>Milled Parts\u003C/h4>\u003Cul>\u003Cli>Are milling fixtures available?\u003C/li>\u003Cli>Is the milling program available?\u003C/li>\u003C/ul>\u003Ch4>Punched / Die-Cut Parts\u003C/h4>\u003Cul>\u003Cli>Are the required punching tools available?\u003C/li>\u003C/ul>\u003Ch3>10. Material Data Sheet\u003C/h3>\u003Cul>\u003Cli>Can you provide a material data sheet for the processed material?\u003C/li>\u003C/ul>\u003Cp>This ensures that parts can be manufactured identically after the tool transfer.\u003C/p>\u003Ch3>11. Sample Parts\u003C/h3>\u003Cp>Are sample parts available that you can provide to us for evaluation? formary uses these samples for:\u003C/p>\u003Cul>\u003Cli>Dimensional analyses\u003C/li>\u003Cli>Surface comparisons\u003C/li>\u003Cli>Functional testing\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:974/774;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/image_22_1_f204d88053.webp\" alt=\"Musterteile Tiefziehen\" width=\"974\" height=\"774\">\u003C/figure>\u003Ch2>Tool Transfer Checklist\u003C/h2>\u003Cp>The following checklist summarizes which information is required for a fast and secure tool transfer:\u003C/p>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Category\u003C/th>\u003Cth>Required Information\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>CAD Data\u003C/td>\u003Ctd>3D/2D files, tool geometry\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Images\u003C/td>\u003Ctd>Detailed photos, condition, vacuum ports\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Dimensions\u003C/td>\u003Ctd>Tool dimensions, base plate\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Additional Elements\u003C/td>\u003Ctd>Frame, substructure, top plug\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Machine Information\u003C/td>\u003Ctd>Previously used machine type\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Cavities\u003C/td>\u003Ctd>Number of forming cavities\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Cooling\u003C/td>\u003Ctd>Type of tool cooling\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Trimming Tools\u003C/td>\u003Ctd>Milling fixture, milling program, or punching tool\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Material\u003C/td>\u003Ctd>Data sheet of the material used\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Sample Parts\u003C/td>\u003Ctd>Samples for evaluation\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Chr>\u003Ch2>Frequently Asked Questions About Thermoforming Tool Transfer\u003C/h2>\u003Ch4>What is tool transfer in thermoforming?\u003C/h4>\u003Cp>Tool transfer refers to the continued use of an existing thermoforming tool at a new manufacturer without the need to build a new tool.\u003C/p>\u003Ch4>How does the transfer of thermoforming tools work?\u003C/h4>\u003Cp>An existing tool is technically inspected, adapted if necessary, matched to the new machine, and then used for sampling and series production.\u003C/p>\u003Ch4>When does a tool transfer make sense?\u003C/h4>\u003Cp>Whenever the tool is still functional. Tool transfer reduces costs, enables faster production start-ups, and ensures that existing part geometries can continue to be produced unchanged.\u003C/p>\u003Ch4>Can every thermoforming tool be transferred?\u003C/h4>\u003Cp>In most cases, yes. The decisive factors are the tool’s condition, material, design, and machine compatibility.\u003C/p>\u003Ch4>How long does a thermoforming tool transfer take?\u003C/h4>\u003Cp>In many cases, a transfer is significantly faster than building a new tool. The more complete the available data, the quicker series production can begin.\u003C/p>\u003Ch4>For which industries is tool transfer particularly useful?\u003C/h4>\u003Cp>Transfers are used in any industry where series products need to be manufactured consistently over many years. Examples include \u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">medical technology\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/mechanical-engineering\">mechanical engineering\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/electronics\">electronics\u003C/a>, \u003Ca href=\"https://www.formary.de/en/industries/thermoformed-parts-for-automotive\">automotive\u003C/a>, and \u003Ca href=\"https://www.formary.de/en/industries/industrial-solutions\">industry\u003C/a>.\u003C/p>\u003Ch4>For which products is tool transfer particularly suitable?\u003C/h4>\u003Cp>For \u003Ca href=\"https://www.formary.de/en/solutions/plastic-covers\">housings\u003C/a>, \u003Ca href=\"https://www.formary.de/en/solutions/plastic-containers\">containers\u003C/a>, \u003Ca href=\"https://www.formary.de/en/solutions/trays-for-production-automation\">trays\u003C/a>, \u003Ca href=\"https://www.formary.de/en/solutions/plastic-inlays\">inserts\u003C/a>, and all components with long product life cycles.\u003C/p>\u003Ch4>Which thermoformed parts benefit most from the reuse of existing tools?\u003C/h4>\u003Cp>Above all, components that are manufactured in long product life cycles, require precise fits, and are regularly reproduced.\u003C/p>\u003Chr>\u003Ch2>Conclusion: Tool transfer as a fast and economical route to series production\u003C/h2>\u003Cp>Tool transfer in deep drawing is one of the most efficient ways to continue producing existing components without delay and without incurring new tooling costs. Companies benefit from validated product quality and fast, cost-efficient series production. With formary, you receive a technical review within a very short time and secure integration of your tool into production.\u003C/p>\u003Cp>Are you currently planning your deep drawing project? Then \u003Ca href=\"https://www.formary.de/en/contact\">\u003Cstrong>contact\u003C/strong>\u003C/a> us—we will support you from the initial idea to implementation.\u003C/p>","tool-transfer-in-thermoforming",{"id":945,"documentId":946,"createdAt":947,"updatedAt":947,"publishedAt":948,"locale":10,"title":949,"introduction":950,"content":951,"slug":952},475,"vn26k1zejmlc8gq15o6px5gz","2026-01-26T14:15:04.835Z","2026-01-26T14:15:04.882Z","The Biggest Challenges for Manufacturing Companies & Supply Chain Management in 2026","Supply chains have never been as complex and volatile as they are today: geopolitical tensions, capacity bottlenecks, rising raw material prices worldwide, and national energy costs. Companies that want to remain competitive must reassess their supply chain management (SCM).","\u003Ch2>\u003Cspan style=\"color:#005250;\">Current Challenges in Procurement & Supply Chain Management – Key Takeaways\u003C/span>\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Increasing time pressure:\u003C/strong> Product life cycles continue to shorten, while quotation and development processes in many companies – including smaller ones – take too long.\u003C/li>\u003Cli>\u003Cstrong>Growing supply chain risks:\u003C/strong> Corporations and large SMEs increasingly rely on multi-sourcing and early warning systems to mitigate geopolitical risks and disruptions.\u003C/li>\u003Cli>\u003Cstrong>Lack of cost transparency:\u003C/strong> Prices and manufacturability are opaque; fragmented manufacturing markets make quotation comparisons difficult – often the most efficient supplier is not selected.\u003C/li>\u003Cli>\u003Cstrong>Rising quality management (QM) risks:\u003C/strong> Inspection reports are missing; QM responsibilities and certifications are unclear. Manufacturing topics such as tolerances and surfaces are clarified too late.\u003C/li>\u003Cli>\u003Cstrong>Unclear project status:\u003C/strong> Without digital tracking, order processes remain intransparent. Delays are communicated too late.\u003C/li>\u003Cli>\u003Cstrong>Lack of technical consulting:\u003C/strong> Suppliers too often act purely as contract manufacturers without advising on design, materials, or application.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">What Are the Biggest Supply Chain Management Challenges in 2026?\u003C/span>\u003C/h2>\u003Cp>The new year 2026 will confront procurement in manufacturing companies with profound changes. This applies in particular to the growing supply chain management challenges – ranging from global dependencies to massive planning volatility. The most significant challenges include:\u003C/p>\u003Col>\u003Cli>Increasing time pressure\u003C/li>\u003Cli>Unstable supply chains\u003C/li>\u003Cli>Lack of end-to-end transparency\u003C/li>\u003Cli>Rising cost pressure\u003C/li>\u003Cli>High quality and documentation requirements\u003C/li>\u003Cli>Missing technical consulting\u003C/li>\u003C/ol>\u003Cp>More details in the sections below.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Time Pressure Due to Shorter Product Life Cycles\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1200/400;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Zeit_ist_geld_1_99b781d148.png\" alt=\"Hand, die eine Uhr hält \" width=\"1200\" height=\"400\">\u003C/figure>\u003Cp>Product life cycles are becoming shorter, while many quotation and procurement processes are outdated. Time-consuming manual coordination, a lack of automation, and lengthy internal approval steps delay quotations, lead times, and production releases.\u003C/p>\u003Cp>To address these challenges, companies are increasingly adopting scenario simulations and automated forecasting processes to better plan tooling and material capacities and optimize procurement processes.\u003C/p>\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 Especially in \u003Ca href=\"https://www.formary.de/en/plastic-thermoforming\"> plastic thermoforming, \u003C/a> where tooling costs, \u003Ca href=\"https://www.formary.de/en/materials\"> material selection \u003C/a>  and first article inspections are critical, delays occur quickly and can push market launches back by weeks.\u003C/p>\n    \u003C/div>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Supply Chain Risk & Resilience Pressure\u003C/span>\u003C/h3>\u003Cp>Large companies today expect supply chains not only to cope with disruptions but to actively anticipate them. Key developments include:\u003C/p>\u003Cul>\u003Cli>Multi-sourcing instead of single sourcing\u003C/li>\u003Cli>Early warning systems & control towers\u003C/li>\u003Cli>Collaborative supplier models\u003C/li>\u003C/ul>\u003Cp>These trends clearly show that companies must actively address supply chain management challenges to secure resilience and competitiveness.\u003C/p>\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 plastic thermoformed parts, this means companies can no longer rely on single, historically grown suppliers—regardless of location or region. Global supply chains require regional redundancies to minimize geopolitical, logistical, and \u003Ca href=\"https://www.formary.de/en/blog/material-shortage-how-formary-can-help\"> material supply \u003C/a>  risks. Otherwise, companies face significant risks, especially in series projects with short time-to-market requirements.\u003C/p>\n    \u003C/div>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Lack of Cost Transparency in the Procurement Market\u003C/span>\u003C/h3>\u003Cp>In many B2B manufacturing processes, including plastic thermoforming, quotations are rarely directly comparable. Key reasons include:\u003C/p>\u003Cul>\u003Cli>Machinery and automation levels (cycle times, complexity)\u003C/li>\u003Cli>Different tooling concepts\u003C/li>\u003Cli>Variable costing methodologies\u003C/li>\u003Cli>Material strategies (purchasing prices, stock materials, in-house extrusion)\u003C/li>\u003Cli>Margin structures depending on current capacity utilization\u003C/li>\u003C/ul>\u003Cp>This lack of price transparency has become an underestimated supply chain management challenge, as it directly affects planning reliability and procurement efficiency. Traditional negotiations are no longer sufficient: companies require data-driven analysis tools, price benchmarks, and manufacturability assessments to make robust decisions.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Insufficient Quality Assurance Across the Project Lifecycle\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:1536/1024;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Qualitaet_und_Sicherheit_im_Thermoforming_gewaehrleisten_6c7b4c4ea4.webp\" alt=\"Fehlende Qualitätssicherung als eine der großen SCM Herausforderungen\" width=\"1536\" height=\"1024\">\u003C/figure>\u003Cp>A frequent bottleneck in supply chain management is \u003Ca href=\"https://www.formary.de/en/quality-assurance\">quality management (QM).\u003C/a> Typical issues include:\u003C/p>\u003Cul>\u003Cli>Unclear QM responsibilities\u003C/li>\u003Cli>Missing or incomplete inspection reports\u003C/li>\u003Cli>Late definition of critical specifications (tolerances, surfaces, material behavior)\u003C/li>\u003Cli>Lack of early warning systems for deviations\u003C/li>\u003C/ul>\u003Cp>The combination of quality risks and supply chain complexity significantly amplifies SCM challenges throughout the entire project lifecycle. Without end-to-end QM processes, uncertainty arises in production and first article inspection, leading to rework, delays, and increased risks in series production.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">5. Intransparent Order Processing\u003C/span>\u003C/h3>\u003Cp>Once orders are placed, they often turn into a \u003Cstrong>black box\u003C/strong>:\u003C/p>\u003Cul>\u003Cli>What is the project status?\u003C/li>\u003Cli>When is the next milestone?\u003C/li>\u003Cli>Have approvals been granted?\u003C/li>\u003C/ul>\u003Cp>Without structured project communication and digital traceability, status information is quickly lost. The result is misunderstandings, delayed deliveries, and high internal coordination effort.\u003C/p>\u003Cp>In 2026, transparency in supply chains will be a fundamental requirement: control tower models, tracking tools, and real-time data are becoming essential to make risks visible, increase responsiveness, and resolve critical supply chain management challenges.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">6. Little to No Technical Consulting\u003C/span>\u003C/h3>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg style=\"aspect-ratio:5184/3456;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Lieferant_werden_formary_288c639794.jpg\" alt=\"Fehlende technische Beratung als Supply Chain Management Herausforderung\" width=\"5184\" height=\"3456\">\u003C/figure>\u003Cp>Many manufacturers see themselves merely as executors of CAD data. Active technical consulting often does not take place. Common consequences include:\u003C/p>\u003Cul>\u003Cli>Technical questions remain unanswered\u003C/li>\u003Cli>Special requirements are not reviewed\u003C/li>\u003Cli>Lack of material and design optimization\u003C/li>\u003C/ul>\u003Cp>Yet consulting on material selection, \u003Ca href=\"https://www.formary.de/en/blog/design-for-manufacturing-guide\">design for manufacturability,\u003C/a> and application engineering would be a key lever in addressing current procurement challenges and achieving economically and functionally optimal products.\u003C/p>\u003Ch4>Overview: Key Challenges in Procurement and Supply Chain Management 2026\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Challenge\u003C/th>\u003Cth>Classification\u003C/th>\u003Cth>Impact on Companies\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Time pressure & shorter product life cycles\u003C/strong>\u003C/td>\u003Ctd>Outdated procurement processes, long quotation and approval cycles slow down projects.\u003C/td>\u003Ctd>Delayed market entry & rising internal costs\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Supply chain & resilience pressure\u003C/strong>\u003C/td>\u003Ctd>Geopolitical risks, material shortages, and the need for multi-sourcing and early warning systems.\u003C/td>\u003Ctd>Greater dependency & risk of unstable supply chains\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Lack of cost transparency\u003C/strong>\u003C/td>\u003Ctd>Prices, material costs, and manufacturability are difficult to compare; fragmented market.\u003C/td>\u003Ctd>Unreliable cost calculations & more difficult purchasing decisions\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Quality and QA risks\u003C/strong>\u003C/td>\u003Ctd>Missing inspection reports, late definition of specifications, and inconsistent quality management.\u003C/td>\u003Ctd>Higher scrap rates, rework & scheduling risks\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Project & process intransparency\u003C/strong>\u003C/td>\u003Ctd>Order status often remains unclear due to missing digital tracking.\u003C/td>\u003Ctd>Increased communication effort; unreliable delivery schedules\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Lack of technical consulting\u003C/strong>\u003C/td>\u003Ctd>Suppliers often act solely as executors without material or design input.\u003C/td>\u003Ctd>Unoptimized components, higher costs & technical risks\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Which Companies Are Most Affected by Current Supply Chain Risks and Procurement Challenges?\u003C/span>\u003C/h2>\u003Cp>Manufacturing companies particularly affected include those with:\u003C/p>\u003Cul>\u003Cli>High product variant diversity\u003C/li>\u003Cli>Short product life cycles\u003C/li>\u003Cli>International supply chains\u003C/li>\u003Cli>High quality and documentation requirements\u003C/li>\u003C/ul>\u003Cp>This includes sectors such as \u003Ca href=\"https://www.formary.de/en/industries/mechanical-engineering\">mechanical engineering,\u003C/a> \u003Ca href=\"https://www.formary.de/en/industries/medical-pharmaceutical-applications\">medical technology,\u003C/a> \u003Ca href=\"https://www.formary.de/en/industries/electronics\">electronics,\u003C/a> \u003Ca href=\"https://www.formary.de/en/industries/thermoformed-parts-for-automotive\">automotive,\u003C/a> and \u003Ca href=\"https://www.formary.de/en/industries/industrial-solutions\">industrial manufacturing.\u003C/a>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">How formary Systematically Solves These Challenges in the Procurement of Plastic Thermoformed Parts\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg style=\"aspect-ratio:1920/1080;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/English_formary_Website_Mockup_0829d25eeb.webp\" alt=\"English formary Website Mockup\" width=\"1920\" height=\"1080\">\u003C/figure>\u003Cp>These procurement challenges are particularly evident in plastic thermoformed parts: missing data, a fragmented supplier market, and major price differences complicate fast and secure decision-making. Rather than applying isolated solutions, formary digitizes and structures the entire procurement process for plastic thermoformed parts.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Accelerated Processes and Reduced Time-to-Market\u003C/span>\u003C/h3>\u003Cp>formary fully digitizes inquiry, quotation, and project execution:\u003C/p>\u003Cul>\u003Cli>Structured inquiry \u003Ca href=\"https://www.formary.de/en/configurator\">configurator\u003C/a> with CAD upload\u003C/li>\u003Cli>Complete requests without manual follow-ups\u003C/li>\u003Cli>Quotations within 24 hours\u003C/li>\u003Cli>Integrated \u003Ca href=\"https://www.formary.de/en/3d-services/dfm-analyse\">design-for-manufacturing analysis\u003C/a>\u003C/li>\u003C/ul>\u003Cp>As a result, project timelines are significantly shortened. Time-to-prototype is reduced from \u003Cstrong>6–8 weeks to 2–3 weeks\u003C/strong>, and overall project duration decreases by \u003Cstrong>up to 70%\u003C/strong>.\u003C/p>\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 \u003Cb>Practical example:\u003C/b> The collaboration with \u003Ca href=\"https://www.formary.de/en/case-studies/i-thera-medical-1\"> iThera Medical \u003C/a>  demonstrates how effective this acceleration can be. For a new generation of devices, the MedTech company required \u003Ca href=\"https://www.formary.de/en/products/medical-covers\"> medical enclosures \u003C/a> with demanding technical requirements and extremely short lead times.\n\u003Cbr>\n\u003Cbr>\nformary optimized the design for cost efficiency, flexibly distributed manufacturing across its network, and organized alternative material sources when a supplier failed. The result: on-time, high-precision prototypes despite material shortages – and around 50% cost reduction in the project.\u003C/p>\n    \u003C/div>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transparent Costs and Reliable Comparability\u003C/span>\u003C/h3>\u003Cp>formary creates cost transparency through:\u003C/p>\u003Cul>\u003Cli>AI-powered supplier matching\u003C/li>\u003Cli>Direct manufacturer pricing without hidden markups\u003C/li>\u003Cli>Uniformly structured quotations in the customer portal\u003C/li>\u003C/ul>\u003Cp>Procurement teams gain reliable decision-making data and reduce project costs by \u003Cstrong>up to 30%\u003C/strong>.\u003C/p>\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 Learn more in our article: \u003Ca href=\"https://www.formary.de/en/blog/5-levers-formary-uses-to-reduce-thermoforming-costs\"> 5 Levers formary Uses to Reduce Thermoforming Costs.\u003C/a> \u003C/p>\n    \u003C/div>\u003C/div>\u003Ch3>\u003Cspan style=\"color:#005250;\">End-to-End Quality Assurance from the Start\u003C/span>\u003C/h3>\u003Cp>Quality assurance is an integral part of the formary process:\u003C/p>\u003Cul>\u003Cli>Exclusively audited, ISO-certified partner network\u003C/li>\u003Cli>Digital DfM analysis with simulation of critical geometries\u003C/li>\u003Cli>Complete QA and inspection report documentation\u003C/li>\u003Cli>Clear responsibilities throughout the entire project lifecycle\u003C/li>\u003C/ul>\u003Cp>Errors are detected early—before they become costly in tooling or series production.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg style=\"aspect-ratio:131/150;\" src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Toleranzen_Icon_d0b3f87455.svg\" alt=\"Durchgängige Qualitätssicherung\" width=\"131\" height=\"150\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Transparent and Controllable Order Processing\u003C/span>\u003C/h3>\u003Cp>Through the formary \u003Ca href=\"https://www.formary.de/en/account/login\">customer portal,\u003C/a> companies retain full visibility at all times:\u003C/p>\u003Cul>\u003Cli>Real-time project status\u003C/li>\u003Cli>Digital approvals of CAD data and \u003Ca href=\"https://www.formary.de/en/prototyping\">prototypes\u003C/a>\u003C/li>\u003Cli>Delivery and shipment tracking\u003C/li>\u003Cli>Centralized storage of all project documentation\u003C/li>\u003C/ul>\u003Cp>This makes order processing predictable and traceable.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Technical Consulting Instead of Pure Contract Manufacturing\u003C/span>\u003C/h3>\u003Cp>formary acts as a \u003Cstrong>single point of contact\u003C/strong> and assumes technical responsibility:\u003C/p>\u003Cul>\u003Cli>Consulting on materials, design, and feasibility\u003C/li>\u003Cli>Combination of digital tools (such as the \u003Ca href=\"https://www.formary.de/en/3d-services/tray-generator\">3D tray generator\u003C/a>), DfM analysis, and manufacturing expertise\u003C/li>\u003Cli>Support from prototype to series production (see: \u003Ca href=\"https://www.formary.de/en/blog/project-planning-in-thermoforming\">Project Planning in Thermoforming\u003C/a>)\u003C/li>\u003C/ul>\u003Ch4>Benefits of formary in the Procurement Process\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>formary Benefit\u003C/th>\u003Cth>What formary Provides\u003C/th>\u003Cth>Concrete Value for Companies\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>\u003Cstrong>Accelerated project timelines\u003C/strong>\u003C/td>\u003Ctd>Inquiry, quotation, and execution are fully digitized: quotations within 24 hours, time-to-prototype reduced from 6–8 to 2–3 weeks.\u003C/td>\u003Ctd>Faster market entry, shorter development cycles, reduced coordination effort\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Transparent costs & comparability\u003C/strong>\u003C/td>\u003Ctd>AI-driven supplier matching and direct manufacturer pricing create clarity without markups.\u003C/td>\u003Ctd>Up to 30% cost savings and a reliable decision-making basis\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>End-to-end quality assurance\u003C/strong>\u003C/td>\u003Ctd>ISO-certified partners, DfM analyses, and complete inspection reports integrated into the process.\u003C/td>\u003Ctd>Early error detection and fewer production and series risks\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Digital order & project transparency\u003C/strong>\u003C/td>\u003Ctd>Real-time status, digital approvals, shipment tracking, and a document portal.\u003C/td>\u003Ctd>Predictable supply chains, less coordination effort, higher process reliability\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Technical consulting & know-how\u003C/strong>\u003C/td>\u003Ctd>formary delivers design, material, and feasibility consulting instead of pure manufacturing.\u003C/td>\u003Ctd>Optimized components, fewer revision loops, lower risk of misinvestment\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>\u003Cstrong>Flexible manufacturing network\u003C/strong>\u003C/td>\u003Ctd>Distributed manufacturing and alternative sources prevent bottlenecks in case of supplier failures.\u003C/td>\u003Ctd>Higher resilience and reduced supply chain risk\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Frequently Asked Questions About Supply Chain Management Challenges & Thermoformed Part Procurement\u003C/span>\u003C/h2>\u003Ch4>What are the biggest supply chain management challenges in 2026?\u003C/h4>\u003Cp>They include increasing time pressure, unstable supply chains, lack of end-to-end transparency, rising cost pressure, and high quality and documentation requirements.\u003C/p>\u003Ch4>Why do supply chain management challenges become a competitive factor in 2026?\u003C/h4>\u003Cp>Companies that fail to evolve their procurement and supply chain processes lose speed, planning reliability, and cost efficiency.\u003C/p>\u003Ch4>Why is traditional procurement no longer sufficient in 2026?\u003C/h4>\u003Cp>Because it is too slow, too intransparent, and too reactive to manage complex supply chains effectively.\u003C/p>\u003Ch4>What does time-to-market mean in procurement?\u003C/h4>\u003Cp>It refers to the time from product design to series readiness. Delayed quotations and lengthy coordination extend this time and reduce competitiveness.\u003C/p>\u003Ch4>Why is cost transparency important?\u003C/h4>\u003Cp>It enables comparable quotations, better partner selection, and reduces unexpected costs through clear pricing and manufacturability insights.\u003C/p>\u003Ch4>What role does quality assurance play in procurement?\u003C/h4>\u003Cp>Quality assurance ensures compliance with specifications. Missing reports and late tolerance definitions increase error and rework risks.\u003C/p>\u003Ch4>How does digital traceability improve order processing?\u003C/h4>\u003Cp>Digital systems provide real-time status, prevent information loss, and reduce internal coordination costs.\u003C/p>\u003Ch4>Why is technical consulting relevant?\u003C/h4>\u003Cp>Technical consulting optimizes material selection and design early on. Without it, economic and functional potential often remains untapped.\u003C/p>\u003Chr>\u003Ch2>Conclusion – SCM & Plastic Parts Procurement Must Be Rethought in 2026\u003C/h2>\u003Cp>Procurement processes in 2026 are characterized by increasing time pressure, lack of transparency, and insufficient quality assurance. At the same time, digital project transparency and technical consulting are often missing.\u003C/p>\u003Cp>formary demonstrates how digital, technically sound, and transparent procurement of plastic thermoformed parts can look today—faster, more reliable, and more economical.\u003C/p>\u003Cp>Send us your inquiry or contact us directly with any questions!\u003C/p>","supply-chain-management-challenges-2026",{"id":954,"open_graph_title":632,"open_graph_description":955,"title":632,"description":955},2480,"Thermoformed parts in practice: ✓ Insights into thermoforming ✓ Useful information about plastic thermoforming ▶ We explain all aspects of thermoforming.",[957],{"id":254,"documentId":628,"createdAt":958,"updatedAt":959,"publishedAt":960,"locale":128,"title":961,"slug":962,"description":963},"2026-01-08T23:02:59.586Z","2026-01-26T08:56:15.473Z","2026-01-26T08:56:15.585Z","Tiefziehteile in der Praxis","tiefziehteile-in-der-praxis","Alle Einblicke in die Praxis des Thermoformings. Nützliche Hinweise, was gilt es zu beachten? Hier finden Sie Einträge zu allen Aspekten des Thermoformings.",[],[966],{"id":967,"documentId":463,"createdAt":968,"updatedAt":968,"publishedAt":969,"locale":128,"title":970,"introduction":971,"content":972,"slug":973},320,"2026-01-08T23:07:29.023Z","2026-01-13T11:10:05.550Z","Rapid Prototyping im Tiefziehen - Definition, Vorteile & Verfahren","Rapid Prototyping wird in der Produktentwicklung für die schnelle Vorab-Erstellung von Mustern verwendet. Insbesondere im Tiefziehen bietet Rapid Prototyping eine Fülle von Möglichkeiten, um schnell und kosteneffizient hochwertige Prototypen zu erstellen. ","\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid Prototyping im Tiefziehen - Das Wichtigste in Kürze\u003C/span>\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Rapid Prototyping\u003C/strong> im Tiefziehen beschleunigt die Entwicklung und senkt Werkzeugänderungskosten.\u003C/li>\u003Cli>Es gibt im Tiefziehen \u003Cstrong>vier Rapid Prototyping Verfahren: \u003C/strong>3D-Druck, Ureol, Teilsegment- und Serienwerkzeug.\u003C/li>\u003Cli>Rapid Prototyping wird insbesondere in den \u003Cstrong>Branchen \u003C/strong>Automotive, Medizintechnik, Robotik und Verpackungsindustrie eingesetzt.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was ist Rapid Prototyping?\u003C/span>\u003C/h2>\u003Cp>Rapid Prototyping Definition:\u003Cstrong> \u003C/strong>Rapid Prototyping oder Fast Prototyping (übers. \u003Ci>schnelle Prototypenherstellung)\u003C/i> bezieht sich auf den Prozess der schnellen und effizienten Erstellung physischer Modelle oder \u003Ca href=\"https://www.formary.de/prototypen\">Prototypen\u003C/a> eines Bauteils oder einer Baugruppe basierend auf dreidimensionalen CAD-Daten / \u003Ca href=\"https://www.formary.de/blog/freigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten\">Konstruktionsdaten\u003C/a>. Der Prototyp dient als erste Version des Produkts, das vor der Massenproduktion gründlich getestet und gegebenenfalls überarbeitet wird.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Wozu dient Rapid Prototyping?\u003C/span>\u003C/h2>\u003Col>\u003Cli>\u003Cstrong>Schnelligkeit\u003C/strong>: Durch den Einsatz von Rapid Prototyping können Prototypen in kürzester Zeit hergestellt werden, was den Entwicklungsprozess erheblich beschleunigt.\u003C/li>\u003Cli>\u003Cstrong>Flexibilität\u003C/strong>: Der Rapid Prototyping Prozess ermöglicht es, schnell Änderungen oder Korrekturen an Prototypen vorzunehmen, um das Endprodukt zu verbessern.\u003C/li>\u003Cli>\u003Cstrong>Kürzere \u003C/strong>\u003Ci>\u003Cstrong>go to market\u003C/strong>\u003C/i>\u003Cstrong> Zeiten:\u003C/strong> Die Herstellung und Lieferung von Prototypen verkürzt sich durch die Anwendung von Rapid Prototyping. Das führt dazu, dass Produkte schneller auf den Markt gebracht werden.\u003C/li>\u003C/ol>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid Prototyping Vorteile\u003C/span>\u003C/h2>\u003Cul>\u003Cli>Frühes Erkennen von Verbesserungen im Designprozess\u003C/li>\u003Cli>Kosteneffizienz\u003C/li>\u003Cli>Hohe Präzision dank computergestütztem Design\u003C/li>\u003Cli>Reduziertes Risiko teurer Fehler\u003C/li>\u003Cli>Ermöglichung der Präsentation und Feedback mit physischen Prototypen\u003C/li>\u003Cli>Integration von kostengünstigen Kundenanforderungen\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">Welche Arten von Rapid Prototyping Verfahren gibt es im Tiefziehen?\u003C/span>\u003C/h2>\u003Cp>Es bieten sich beim Rapid Prototyping 4 Optionen an, abhängig vom Sinn und Zweck der Muster. In den folgenden Abschnitten finden Sie eine Übersicht der Rapid Prototyping Verfahren.  \u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping mit 3D-Druck Werkzeug\u003C/span>\u003C/h3>\u003Cp>Der Einsatz von 3D-gedruckten \u003Ca href=\"https://www.formary.de/blog/tiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugen\u003C/a> ist häufig zur Bemusterung wichtiger Teilsegmente in Tiefziehprozessen anzutreffen. Aufgrund der auftretenden Temperaturen und Belastungen während des Tiefziehens können jedoch nur eine kleine Anzahl an Mustern aus einem 3D-gedruckten Werkzeug hergestellt werden.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:37.13%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/3_D_Druck_Werkzeug_e31f8571e4.png\" alt=\"Rapid Prototyping mit 3D-Werkzeugen\">\u003Cfigcaption>Rapid Prototyping mit 3D-Werkzeugen\u003C/figcaption>\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">3D-Druck Prototypen\u003C/span>\u003C/h4>\u003Cul>\u003Cli>Maximale Anzahl der Muster: 1-3 Stück\u003C/li>\u003Cli>Fertigungszeitraum (best case): 3-5 Arbeitstage\u003C/li>\u003Cli>Preis: \u003Cspan style=\"color:#00a9a5;\">€\u003C/span>\u003Cspan style=\"color:#c2c2c2;\">€€€€\u003C/span>\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:#005250;\">Anwendungsbereiche von 3D-Druck Prototypen\u003C/span>\u003C/h4>\u003Cp>Der Einsatzbereich liegt daher im Test von Formnest-Passungen, sehr schnell benötigten Prototypen innerhalb weniger Tage, sowie eine Kleinserie im Standard-Material.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Übersicht der Vorteile und Nachteile von Rapid Prototyping mit 3D-Druck Werkzeugen\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Vorteile beim Rapid Prototyping mit 3D-Druck\u003C/th>\u003Cth>Nachteile beim Rapid Prototyping mit 3D-Druck\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>3D-gedruckte Werkzeuge sind oft kostengünstig\u003C/td>\u003Ctd>Der 3D-Druck, abhängig vom gewählten Verfahren, hat eine spezifische Oberfläche, die bei unbearbeitetem 3D-Druck in der Oberfläche des Tiefziehteils zu sehen sein wird. Optische Teile scheiden daher für Prüfungs- oder Vorführzwecke beinahe unwillkürlich aus. Auch sind durch das Schichtverfahren bei FDM keine realistischen Kanten und Radien zu erschaffen, was die Aussagekraft weiter schmälert\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Schnelle Durchführung von Passformtests bei Tray-Formnestern\u003C/td>\u003Ctd>Einige Materialien, wie bsp. PP, lassen sich nur optimal unter Verwendung von temperierten Serienwerkzeugen formen\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping mit Musterwerkzeug aus Ureol\u003C/span>\u003C/h3>\u003Cp>Ureol ist ein Blockmaterial für den Modellbau. Werkzeuge aus Ureol können entweder Teilsegmente oder das gesamte Endprodukt abbilden. Das Resultat ähnelt oft schon sehr den Serien-Tiefziehteilen aus Aluminiumwerkzeugen. \u003C/p>\u003Cp>Die Fräszeiten für die Herstellung von Ureol-Werkzeugen sind zwar vergleichbar lang wie bei Aluminium, jedoch ist das Material kostengünstiger. Aufgrund der geringeren Hitze- und Druckbeständigkeit von Ureol sind jedoch nur wenige Muster möglich.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:47.59%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Musterwerkzeug_aus_Ureol_e5f2632c17.png\" alt=\"Rapid Prototyping mit Musterwerkzeugen aus Ureol\">\u003Cfigcaption>Rapid Prototyping mit Musterwerkzeugen aus Ureol\u003C/figcaption>\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ureol-Werkzeug Prototypen\u003C/span>\u003C/h4>\u003Cul>\u003Cli>Maximale Anzahl der Muster: 5-10 Stück\u003C/li>\u003Cli>Fertigungszeitraum (best case): 1-2 Wochen\u003C/li>\u003Cli>Preis: \u003Cspan style=\"color:#00a9a5;\">€€\u003C/span>\u003Cspan style=\"color:#c2c2c2;\">€€€\u003C/span>\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:#005250;\">Anwendungsbereiche von Ureol-Werkzeug Prototypen\u003C/span>\u003C/h4>\u003Cp>Das Resultat ist ein zum 3D-Druck optimiertes Musterergebnis, das minimal länger dauert und minimal mehr kostet.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Übersicht der Vorteile und Nachteile von Rapid Prototyping mit Musterwerkzeugen aus Ureol\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Vorteile beim Rapid Prototyping mit Musterwerkzeug aus Ureol\u003C/th>\u003Cth>Nachteile beim Rapid Prototyping mit Musterwerkzeug aus Ureol\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Die hergestellten Muster sind nahezu serienreif, weisen jedoch geringfügige Qualitätsunterschiede im Vergleich zu Aluminiumwerkzeugen auf\u003C/td>\u003Ctd>Zusätzliche Kosten: Das Ureol-Werkzeug fungiert lediglich als Zwischenschritt vor der Produktion des Serienwerkzeugs\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Der Preis liegt nur bei etwa 20-30% des Preises eines Serienwerkzeugs, je nach Kontur und Komplexität der Fräsarbeiten\u003C/td>\u003Ctd>Das Serienwerkzeug wird erst nach Genehmigung angefertigt, wodurch sich der Projektzeitplan um weitere 2-3 Wochen verlängert\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping mit Teilsegment-Serienwerkzeug\u003C/span>\u003C/h3>\u003Cp>Ein Teilsegment-Aluminiumwerkzeug bildet das Ergebnis Ihres Tiefziehteils optimal ab und ermöglicht Kostenersparnisse im Vergleich zur Serienproduktion. Dies kann beispielsweise durch die Verwendung eines einfachen Werkzeugs anstelle eines Mehrfach-Kavitäten-Werkzeugs erreicht werden.\u003C/p>\u003Cp>\u003Cstrong>Bitte beachten:\u003C/strong> Das Musterwerkzeug stellt einen Zwischenschritt zum Aluminium-Serienwerkzeug dar, und die zusätzliche Zeit für dessen Herstellung muss in der \u003Ca href=\"https://www.formary.de/blog/projektplanung-im-thermoforming\">Projektplanung\u003C/a> berücksichtigt werden.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:42.89%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Teilsegment_Serienwerkzeug_ab27e3a164.png\" alt=\"Rapid Prototyping mit Teilsegment-Serienwerkzeug\">\u003Cfigcaption>Rapid Prototyping mit Teilsegment-Serienwerkzeug\u003C/figcaption>\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Teilsegment-Serienwerkzeug Prototypen\u003C/span>\u003C/h4>\u003Cul>\u003Cli>Maximale Anzahl der Muster: unbegrenzt\u003C/li>\u003Cli>Fertigungszeitraum (best case): 2-3 Wochen\u003C/li>\u003Cli>Preis: \u003Cspan style=\"color:#00a9a5;\">€€€\u003C/span>\u003Cspan style=\"color:#c2c2c2;\">€€\u003C/span>\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:#005250;\">Anwendungsbereiche von Teilsegment Serienwerkzeug Prototypen\u003C/span>\u003C/h4>\u003Cp>Test eines Teilsegments unter Serienwerkzeug Voraussetzungen liefert das realistischste Ergebnis zum Serienergebnis. Die Learnings sollten möglichst vom Teilsegment auf das komplette Tray abstrahiert werden können.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Übersicht der Vorteile und Nachteile von Rapid Prototyping mit Teilsegment-Serienwerkzeugen\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Vorteile beim Rapid Prototyping mit Teilsegment-Serienwerkzeugen\u003C/th>\u003Cth>Nachteile beim Rapid Prototyping mit Teilsegment-Serienwerkzeugen\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Das Teilsegment reproduziert die Konturen in einer Qualität, die der Serienproduktion nahekommt\u003C/td>\u003Ctd>Die Herstellung des Serienwerkzeugs erfolgt erst nach Freigabe, wodurch sich der Projektzeitplan um weitere 2-3 Wochen verlängert\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Je nach Größe beträgt der Preis nur einen Bruchteil des gesamten Serienwerkzeugs\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Nach Freigabe kann das Teilsegment für die Serienproduktion angepasst werden\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Rapid Prototyping mit Serienwerkzeug\u003C/span>\u003C/h3>\u003Cp>Das Serienwerkzeug aus Aluminium wird auch zur Herstellung von Freigabemustern verwendet. Die Tiefziehteile aus diesem Werkzeug werden unter optimalen Bedingungen hinsichtlich Verstreckung, Hitze- und Kühlverhalten produziert.\u003C/p>\u003Cp>Insbesondere bei mittleren bis hohen Produktionsmengen ist die Produktionsrate pro Zeiteinheit preislich entscheidend, weshalb oft mit großen Mehrfachnutzen-Werkzeugen gearbeitet wird.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Serienwerkzeug_edcc0ae7bc.png\" alt=\"Rapid Prototyping mit Serienwerkzeug\">\u003Cfigcaption>Rapid Prototyping mit Serienwerkzeug\u003C/figcaption>\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Serienwerkzeug Prototypen\u003C/span>\u003C/h4>\u003Cul>\u003Cli>Maximale Anzahl der Muster: unbegrenzt\u003C/li>\u003Cli>Fertigungszeitraum (best case): 2-6 Wochen (abhängig von Größe, Aufbau und Nutzenanzahl, sowie speziell benötigter Komponenten auch bis zu 10 Wochen möglich)\u003C/li>\u003Cli>Preis: \u003Cspan style=\"color:#00a9a5;\">€€€€€\u003C/span>\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:#005250;\">Anwendungsbereiche von Serienwerkzeug Prototypen\u003C/span>\u003C/h4>\u003Cp>Serienwerkzeuge sind in der Erstellungszeit natürlich die Prototyping Methode, die am längsten dauert. Daher wird sie vordergründig für die Freigabe des Serienprodukts vor Serienanlauf verwendet – nicht unbedingt für die empirische Ermittlung von prüfungsrelevanten Stellen, wie Muster-Varianten 1-3.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Übersicht der Vorteile und Nachteile von Rapid Prototyping mit Serienwerkzeugen\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Vorteile beim Rapid Prototyping mit Serienwerkzeugen\u003C/th>\u003Cth>Nachteile beim Rapid Prototyping mit Serienwerkzeugen\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>Hochwertige Serienqualität der Tiefziehteile\u003C/td>\u003Ctd>Möglicher Aufwand für Nachbearbeitungen am Serienwerkzeug\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Keine zusätzlichen Werkzeugkosten vor Beginn der Serienproduktion\u003C/td>\u003Ctd>Serienwerkzeuge haben die längste Herstellungszeit, daher ist es ratsam, bei dringend benötigten Mustern eine vereinfachte Variante zu bevorzugen\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Muster sind in der Regel im Preis des Serienwerkzeugs enthalten\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>Zeitliche Ersparnis, da keine zusätzlichen Freigabeschritte erforderlich sind\u003C/td>\u003Ctd>/\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid Prototyping Anwendungen\u003C/span>\u003C/h2>\u003Cp>Rapid Prototyping im Tiefziehen findet in einer Vielzahl von Branchen Anwendung, darunter:\u003C/p>\u003Cul>\u003Cli>\u003Ca href=\"https://www.formary.de/branchen/automotive\">Automotive:\u003C/a> Prototypen von Fahrzeugteilen wie Armaturenbrettern, Türverkleidungen und Stoßfängern können schnell und kostengünstig hergestellt werden.\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/branchen/medizin-pharma\">Medizintechnik:\u003C/a> Die Herstellung von Prototypen von medizinischen Geräten und \u003Ca href=\"https://www.formary.de/loesungen/kunststoff-abdeckungen-gehaeuse\">Gehäusen\u003C/a> ermöglicht es Herstellern, neue Produkte schnell zu entwickeln und zu testen.\u003C/li>\u003Cli>\u003Cstrong>Verpackungsindustrie\u003C/strong>: Prototypen von Verpackungen und \u003Ca href=\"https://www.formary.de/loesungen/kunststoff-behaeltnisse\">Kunststoffbehältnissen\u003C/a> können erstellt werden, um deren Funktionalität und Ästhetik zu testen, bevor sie in Massenproduktion gehen.\u003C/li>\u003Cli>\u003Ca href=\"https://www.formary.de/branchen/robotik\">Robotik:\u003C/a> Das Tiefziehverfahren ermöglicht in der Robotik High-Speed Prototypen, mit der Möglichkeit, schnell Anpassungen vornehmen zu können.\u003C/li>\u003C/ul>\u003Cdiv class=\"raw-html-embed\">\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 Sie wollen mehr über die Einsatzbereiche von Tiefziehteilen erfahren? Dann lesen Sie unseren Beitrag \u003Ca href=\"https://www.formary.de/blog/kunststoff-tiefziehteile-im-einsatz-anwendungen-im-detail\">Kunststoff Tiefziehteile im Einsatz.\u003C/a>\u003C/p>\n    \u003C/div>\u003C/div>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Häufige Fragen zu Rapid Prototyping im Tiefziehen\u003C/span>\u003C/h2>\u003Ch4>\u003Cspan style=\"color:#005250;\">Was versteht man unter Rapid Prototyping im Tiefziehen?\u003C/span>\u003C/h4>\u003Cp>Rapid Prototyping im Tiefziehen ist die schnelle Fertigung von Kunststoff-Prototypen auf Basis von 3D-CAD-Daten, um Form, Passung und Funktion vor der Serienproduktion zu testen.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Welche Vorteile bietet Rapid Prototyping im Tiefziehen?\u003C/span>\u003C/h4>\u003Cp>Schnelle Herstellung, hohe Flexibilität, frühe Fehlererkennung, geringere Kosten und exakte Ergebnisse durch CAD-gestützte Fertigung.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Welche Rapid Prototyping Verfahren gibt es im Tiefziehen?\u003C/span>\u003C/h4>\u003Cp>Die vier Hauptverfahren sind 3D-Druck-Werkzeug, Ureol-Werkzeug, Teilsegment-Serienwerkzeug und Serienwerkzeug.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Wie lange dauert Rapid Prototyping im Tiefziehen?\u003C/span>\u003C/h4>\u003Cp>Je nach Verfahren zwischen 3 Tagen (3D-Druck) und bis zu 10 Wochen (komplexes Serienwerkzeug).\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">In welchen Branchen wird Rapid Prototyping im Tiefziehen eingesetzt?\u003C/span>\u003C/h4>\u003Cp>Vor allem in der Automobilindustrie, Medizintechnik, Robotik sowie in der Verpackungsindustrie.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Rapid Prototyping im Tiefziehen - Ein Fazit\u003C/span>\u003C/h2>\u003Cp>Rapid Prototyping im Tiefziehen bietet eine Vielzahl von Möglichkeiten, um \u003Cstrong>schnell und kosteneffizient\u003C/strong> hochwertige Prototypen von Teilen und Komponenten zu erstellen. Durch die Kombination von Schnelligkeit und Flexibilität vereinfacht der Fast Prototyping Prozess die Produktentwicklung und ermöglicht es formary, innovative Produkte schneller auf den Markt zu bringen. \u003C/p>\u003Cp>Nehmen Sie jetzt mit uns \u003Ca href=\"https://www.formary.de/kontakt\">Kontakt\u003C/a> auf! \u003C/p>","rapid-prototyping-moeglichkeiten-im-tiefziehen",{"id":677,"documentId":678,"createdAt":679,"updatedAt":680,"publishedAt":681,"locale":10,"title":682,"introduction":683,"content":684,"slug":685,"cover":975,"seo":1026,"blog_author":1081,"blogcategory":1089,"inline_hubspot_form":85,"blocks":1127,"localizations":1128},{"id":976,"documentId":977,"name":978,"alternativeText":682,"caption":16,"width":367,"height":361,"formats":979,"hash":1020,"ext":150,"mime":153,"size":1021,"url":1022,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":1023,"updatedAt":1024,"publishedAt":1025},2173,"soisr6w17vtqjxa0ubt3f4kb"," Design Guidelines for Plastic Thermoformed 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bei Kunststoff Tiefziehteilen - Top 13 Tipps für kunststoffgerechtes Konstruieren","Kunststoff Tiefziehen ist ein komplexer Prozess mit vielen Einflussvariablen, einschließlich Materialqualität, Temperatur, Druck, Geschwindigkeit und Werkzeuggeometrie. Durch Beachtung dieser Regeln lassen sich Fehler im CAD-Design und im Endprodukt vermeiden. formary hat die wichtigsten Konstruktionstipps zusammengefasst.","\u003Ch2>\u003Cspan style=\"color:#005250;\">Gestaltungsregeln bei Kunststoff Tiefziehteilen - Das Wichtigste in Kürze\u003C/span>\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Radien & Wandschrägen:\u003C/strong> Große Radien (mind. 1,5 mm) und Wandschrägen (>2°) erleichtern das Tiefziehen, verhindern Faltenbildung und Materialrisse.\u003C/li>\u003Cli>\u003Cstrong>Umformverhältnis & Wanddicke:\u003C/strong> Das Verhältnis von Höhe zu Breite beeinflusst die Materialverstreckung; Ausgangsstärke und gewünschte Wanddicke müssen frühzeitig berechnet werden.\u003C/li>\u003Cli>\u003Cstrong>Tiefziehgerechte Geometrie:\u003C/strong> Übergänge, Hinterschnitte, Toleranzen und Materialschrumpfung berücksichtigen, um Qualität, Entformbarkeit und Produktionskosten zu optimieren.\u003C/li>\u003C/ul>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">1. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Radien\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Radien_beim_Kunststoffteile_konstruieren_beachten_efb609b27b.png\" alt=\"Radien bei der Konstruktion von Kunststoffteilen\">\u003C/figure>\u003Cp>Bei der Gestaltung von Kunststoffteilen ist es wichtig, immer möglichst großen Radien einzubauen, um das Streckverhalten zu begünstigen. Tiefziehteile sollte man immer mit einem Mindestradius von 1,5mm fertigen. \u003C/p>\u003Cp>Auf der Werkzeugseite ist man auf einen Mindestradius angewiesen, der als sehr grobe Faustregel (da abhängig von vielen Parametern) die Dicke der Ausgangsstärke des Materials nicht unterschreiten sollte.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Umgang mit scharfen Kanten\u003C/span>\u003C/h3>\u003Cp>Wenn scharfe Kanten nötig sind, dann setzen Sie bei der Konstruktion der Kunststoffteile mindestens einen Radius an, der so groß wie die Ausgangsstärke des Materials ist. Wird der Radius kleiner gesetzt, lassen sich die Daten entweder nicht, oder nur sehr umständlich tiefziehen. Außerdem erhöhen sich die Kosten durch längere Werkzeugfräszeiten.\u003Cbr> \u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Radiusmoeglichkeiten_bei_Positiv_und_Negativwerzeugen_f9311cd2dd.png\" alt=\"Radiusmöglichkeiten bei Positiv- und Negativwerzeugen\">\u003C/figure>\u003Cdiv class=\"raw-html-embed\">\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> \u003Cb>Achtung:\u003C/b> Am Tiefziehteil werden die Radien nochmals größer abgebildet als am Werkzeug selbst. Sowohl bei Positiv- als auch bei Negativwerkzeugen kommt es bei Vorgaben möglichst kleiner Radien vor allem darauf an, das Material so eng anliegend in die Ecken zu bekommen wie möglich. Der Radius an der werkzeugabgewandten Seite ergibt sich aus dem Radius der Werkzeugseite, sowie der Materialtype, der Materialverstreckung und der Materialdicke.      \n\u003C/p>\n    \u003C/div>\n\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">2. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Wandschrägen\u003C/span>\u003C/h2>\u003Cp>Den Winkel zwischen der vertikalen Bauteilwand und der Entformrichtung bezeichnet man als Entformungsschräge. Da die Wahl der Entformungsschrägen die Geometrie des Tiefziehteils verändert, müssen die Winkel der Entformungsschrägen frühzeitig festgelegt und in die \u003Ca href=\"https://www.formary.de/blog/freigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten\">Konstruktionsdaten\u003C/a> eingearbeitet werden.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:30%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Konstruktionstipps_fuer_Wandschraegen_am_Tiefziehteil_ad7720e7cc.png\" alt=\"Konstruktionstipps für Wandschrägen am Tiefziehteil\">\u003C/figure>\u003Cp>Designen Sie die vertikalen Wände des Teils möglichst mit Wandschrägen, um eine einfache Entformung ohne optische Makel, wie Markierungen an der Oberfläche zu erreichen.\u003C/p>\u003Ch4>ℹ️ Empfohlene Wandschrägen generell: >2° \u003C/h4>\u003Cul>\u003Cli>Industriestandard für Negativwerkzeuge: 1,5 - 2°\u003C/li>\u003Cli>Industriestandard für Positivwerkzeuge: 4 - 6°\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">3. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Umformverhältnis und Wanddicke\u003C/span>\u003C/h2>\u003Cp>Das Umformverhältnis gibt die Relation zwischen Höhe und Breite\u003Cstrong> \u003C/strong>der zu formenden Fläche wieder. Da das Material auf der begrenzten Fläche in die Tiefe verstreckt wird, dehnt sich dieses beim Umformen aus. Das Umformverhältnis ist hierbei abhängig von der Geometrie des \u003Ca href=\"https://www.formary.de/blog/tiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugs\u003C/a> bzw. des resultierenden Tiefziehteils.\u003C/p>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:29.52%;\">\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>Die sich daraus resultierende Wanddicke lässt sich durch die folgende Formel überschlagen: \u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d2 = F1/F2 * d1\u003C/strong>\u003C/span>\u003C/p>\u003Cul>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>F1\u003C/strong>\u003C/span>\u003Cstrong>: \u003C/strong>Fläche des Materialzuschnitts ohne Spannrand\u003C/li>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>F2: \u003C/strong>\u003C/span>Oberfläche des Tiefziehteils nach Formvorgang\u003Cstrong> \u003C/strong>\u003C/li>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d1:\u003C/strong>\u003C/span>\u003Cstrong> \u003C/strong>Materialausgangsstärke des Materials\u003Cstrong> \u003C/strong>\u003C/li>\u003Cli>\u003Cspan style=\"color:#00a9a5;\">\u003Cstrong>d2:\u003C/strong>\u003C/span>\u003Cstrong> \u003C/strong>Resultierende Wandstärke (Ergebnis)\u003C/li>\u003C/ul>\u003Cp>ℹ️ Mehr zu den Eck- und Kantenradien, Wandschrägen und Umformverhältnissen finden Sie unter \u003Ca href=\"https://www.formary.de/toleranzen\">Toleranzen\u003Cstrong>.\u003C/strong>\u003C/a>\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">4. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Positiv- oder Negativformung und Wanddicke\u003C/span>\u003C/h2>\u003Cp>Je weiter bzw. tiefer das Material beim Thermoformen ins Werkzeug verstreckt wird, desto dünner wird die zurückbleibende Wandstärke. Üblicherweise wird die zu erzielende Wanddicke bestimmt, und dann zurückgerechnet (siehe Punkt 3), wie hoch die Ausgangsstärke des Materials sein muss (sogenanntes “reverse engineering.”)\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Streck- & Ziehverhältnis\u003C/span>\u003C/h3>\u003Cp>Das Streck- oder Ziehverhältnis beim Tiefziehen beschreibt das Längenverhältnis des Materials im Seitprofil (der Ausgangsstärke) und dem tiefgezogenen Tiefziehteil. Grundsätzlich gilt: Positiv geformte Teile führen bei gleicher Kontur zu einem kleineren und daher vorteilhafteren Streckverhältnis als negativ gezogene Teile.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Positiv_und_Negativformung_bei_Kunststoff_Tiefziehen_18c6967a04.png\" alt=\"Positiv- und Negativformung bei Kunststoff Tiefziehen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Wichtige Regeln beim Formvorgang\u003C/span>\u003C/h3>\u003Cp>Durch das viskoelastische Verhalten von Thermoplasten während der Verstreckung gilt es einige Faustregeln beim Formvorgang zu beachten, wenn Sie Kunststoffteile konstruieren:\u003C/p>\u003Cul>\u003Cli>Je kälter das Halbzeug bei der Verstreckung, desto größer die nötige Kraft, es zu verstrecken\u003C/li>\u003Cli>Je schneller die Verformungsgeschwindigkeit, desto größer die nötige Kraft, es zu verstrecken\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:75%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Potenzielle_Schwachstellen_bei_der_Negativ_und_Positivformung_5ec414a3d3.png\" alt=\"Potenzielle Schwachstellen bei der Negativ- und Positivformung\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Positivformung\u003C/span>\u003C/h3>\u003Cp>Bei negativ geformten Teilen liegt die Schwachstelle des Tiefziehteils nach Formung daher im Bodenbereich, da Material vom Rand in den Boden der Werkzeugkavität verstreckt wird. Dabei dünnt das Material aus.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Negativformung\u003C/span>\u003C/h3>\u003Cp>Bei positiv geformten Teilen liegt die Schwachstelle des Tiefziehteils am Rand, da das Material zuerst am Bodenbereich des späteren Tiefziehteils auf das Positivwerkzeug aufsetzt, und den Randbereich nach unten ausdünnt. Zu dünn gewählte Ausgangsstärken und ein schlechtes Umformverhältnis, das heißt die Relation von Öffnungsbreite zu Öffnungstiefe, verschärfen den negativen Effekt zusätzlich.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">5. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Materialverstreckung bei Kavitäten\u003C/span>\u003C/h2>\u003Cp>Aufgrund der Materialverstreckung sollte vor allem bei negativ gezogenen Nestern darauf geachtet werden, dass die Relation von Tiefe zu Breite der Kavität das Verhältnis 1,5 : 1 nicht überschreitet. Je tiefer die Tiefe T der Kavität in Relation zur Breite B, desto mehr dünnt das Material bei Verstreckung aus. Und je größer die Ausdünnung, desto höher die Chancen eines Aufrisses an der Bodenkante.\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/Materialverstreckung_bei_der_Konstruktion_von_Tiefziehteilen_8ae1a4a0ac.png\" alt=\"Materialverstreckung bei der Konstruktion von Tiefziehteilen\">\u003C/figure>\u003Cp>Die Tabelle erklärt die Möglichkeiten verschiedener Ziehverhältnisse bei negativen und positiven Formen:\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Ziehverhältnis bei negativen und positiven Formen beim Konstruieren von Kunststoffteilen\u003C/span>\u003C/h4>\u003Cfigure class=\"table\">\u003Ctable>\u003Cthead>\u003Ctr>\u003Cth>Ziehverhältnis (Tiefe zu Breite)\u003C/th>\u003Cth>positiv\u003C/th>\u003Cth>negativ\u003C/th>\u003C/tr>\u003C/thead>\u003Ctbody>\u003Ctr>\u003Ctd>0,3:1\u003C/td>\u003Ctd>möglich\u003C/td>\u003Ctd>möglich\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>0,5:1\u003C/td>\u003Ctd>möglich\u003C/td>\u003Ctd>+ Oberstempel\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>1:1\u003C/td>\u003Ctd>möglich\u003C/td>\u003Ctd>+ Oberstempel\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>1,5:1\u003C/td>\u003Ctd>Materialverzug an der Grenze\u003C/td>\u003Ctd>Materialverzug an der Grenze\u003C/td>\u003C/tr>\u003Ctr>\u003Ctd>2:1\u003C/td>\u003Ctd>Lässt sich nicht simulieren. Muss getestet werden.\u003C/td>\u003Ctd>Lässt sich nicht simulieren. Muss getestet werden.\u003C/td>\u003C/tr>\u003C/tbody>\u003C/table>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">6. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Übergangskonturen\u003C/span>\u003Cspan style=\"color:#005250;\"> \u003C/span>\u003C/h2>\u003Cp>Wie schon angemerkt: Beim Thermoforming gilt es in der Konstruktion mit Kunststoffen, kleine Radien zu umgehen. Gerade bei passformgenauen Bauteilkavitäten lassen sich Nester unter Einhaltung der vollen Funktionalität in abgeschwächten Konturen deutlich besser tiefziehbar gestalten.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Verbesserte Formbarkeit durch entschärfte Konturen\u003C/span>\u003C/h3>\u003Cp>In Abbildung 1 ist eine schlecht tiefziehbare Kavitätenkontur dargestellt, in Abbildung 2 eine entschärfte Kontur, welche sich gut formen lässt. Durch die Entschärfung der Entformungsschrägen und Radien lässt sich das Tiefziehteil besser ziehen, was die Qualität erhöht. Außerdem wird das Risiko von Aufrissen dadurch minimiert, sowie höhere Reproduzierbarkeiten garantiert.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Uebergangskonturen_als_wichtige_Gestaltungsregel_fuer_Kunststoff_Tiefziehteile_23791459cd.png\" alt=\"Übergangskonturen als wichtige Gestaltungsregel für Kunststoff Tiefziehteile\">\u003C/figure>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Abgemilderte_Hoehenuebergange_bei_der_Konstruktion_von_Kunststoffteilen_3c4e2785f7.png\" alt=\"Abgemilderte Höhenübergange bei der Konstruktion von Kunststoffteilen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Vorteile für Produktion und Kosten\u003C/span>\u003C/h3>\u003Cp>Schlussendlich sind auch die Taktzeiten kürzer, was in einem allgemein erfreulichen, günstigeren Stückpreis mündet. Auch Übergänge von Randkonturen oder Stufenbereichen können durch Schrägen entschärft werden.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Risiken bei kleinen Radien und mögliche Lösungen\u003C/span>\u003C/h3>\u003Cp>Bei zu kleinen Radien besteht gerade beim positiven Formen immer die Gefahr der Faltenbildung beim Tiefziehen. Um Falten zu umgehen, können auch bei der Kunststoff Konstruktion rippenförmige Übergänge angesetzt werden, um eine Falte beim Positiv-Tiefziehen zumindest gezielt zu formen.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Falten_gezielt_bei_der_Konstrukion_von_Kunststoff_Tiefziehteilen_einsetzen_466f8d330d.png\" alt=\"Faltenbildung gezielt konstruieren bei Kunststoffteilen\">\u003Cfigcaption>Faltenbildung durch angedeutete Rippen\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">7. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Hinterschnitte\u003C/span>\u003C/h2>\u003Cp>Hinterschnitte sind Geometrien, die das Teil am einfachen Herauslösen aus dem Tiefziehwerkzeug hindern. Anders als beim Spritzguss gibt es keine zweite Werkzeughälfte, daher erschweren sie die Entformung.\u003C/p>\u003Cp>\u003Cstrong>Tipps:\u003C/strong>\u003C/p>\u003Cul>\u003Cli>Hinterschnitte möglichst vermeiden oder auf ein tiefziehbares Niveau reduzieren.\u003C/li>\u003Cli>Bei Stapel-Elementen oder Klemmungen sind Hinterschnitte oft unvermeidbarl, daher ist eine sorgfältige Konstruktion erforderlich.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">8. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Verarbeitungsschwindung\u003C/span>\u003C/h2>\u003Cp>Denken Sie daran, dass die Verarbeitungsschwindung eines Kunststoff Tiefziehteils ein wichtiger Faktor ist, der die Endgröße und Form beeinflusst. Nach der Entformung schrumpft das Teil aufgrund des Materialverhaltens noch weiter. Diese Schwindung variiert je nach Material und kann auch nach dem Abkühlen des Teils noch bis zu 24 Stunden anhalten. Insbesondere bei teilkristallinen Thermoplasten hört die Nachschwindung nie auf und das Teil kann sich mit der Zeit weiter verkleinern.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Gegenmaßnahmen bei Verarbeitungsschwindung\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Werkzeuggröße unter Berücksichtigung der Schwindung planen.\u003C/li>\u003Cli>Musterprüfung vor Produktionsstart durchführen.\u003C/li>\u003Cli>\u003Cstrong>Faktoren:\u003C/strong> Materialwahl, Entformtemperatur, Extrusion und interne Spannungen.\u003C/li>\u003C/ul>\u003Ch2>\u003Cspan style=\"color:#005250;\">9. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Tiefziehfähige Toleranzen\u003C/span>\u003C/h2>\u003Cp>Tiefziehteile werden für einen Großteil der industriellen und Verpackungs-Anwendungen mit einer Toleranz von +/- ~1 mm konstruiert. Das entspricht dem Toleranzfeld nach ISO 2768-c für das in diesem Produktbereich gängige 120 bis 400mm Längenmaß.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehfaehige_Toleranzen_beim_Konstruieren_von_Kunststoff_Tiefziehteilen_bec9b8d967.png\" alt=\"Tiefziehfähige Toleranzen beim Konstruieren von Kunststoff Tiefziehteilen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Zusätzliche Kosten bei engen Toleranzen\u003C/span>\u003C/h3>\u003Cp>Das Formen von engeren Toleranzen ist meistens mit zusätzlichen Kosten verbunden. Diese sind auf längere Entformzeiten, größere Fertigungsaufwände und/oder längere Taktzeiten zurückzuführen.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\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 Wichtig ist, dass Toleranzen nicht unnötig eng gewählt werden: Das Motto \u003Cb>„So groß wie möglich, so klein wie nötig“\u003C/b> gilt als allgemeine Richtlinie in der Konstruktionsanleitung.     \n\u003C/p>\n    \u003C/div>\n\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">10. Gestaltungsregel bei Kunststoff Tiefziehteilen bei Baugruppen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Befestigungspunkte\u003C/span>\u003C/h2>\u003Cp>Um verschiedene Tiefziehteile oder Baugruppen zusammenzusetzen, sind Befestigungspunkte nötig. Beim sicheren Verschluss von Tiefziehteilen kommen viele Optionen der Verbindungstechnik zum Einsatz. Diese müssen von Anfang an für das kunststoffgerechte Konstruieren wohl überlegt werden.\u003C/p>\u003Cp>Abhängig von der mechanischen Belastung, der Häufigkeit des Öffnens und Verschließens und der Verbindungsstabilität, stehen verschiedene Möglichkeiten zur Erreichung eines Kraftschlusses zur Verfügung.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Befestigungspunkte_anbringen_bei_der_Konstruktion_von_Kunststoffteilen_63583aa096.png\" alt=\"Befestigungspunkte anbringen bei der Konstruktion von Kunststoffteilen\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Schrauben oder Nieten für kraftschlüssige Verbindungen\u003C/span>\u003C/h3>\u003Cp>Bei permanent kraftschlüssigen Verbindungen werden an den Übergangsstellen zwischen zwei Teilen häufig Schrauben oder Nieten an die Tiefziehteile angebracht, um eine Verbindung zu erzielen.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">11. Gestaltungsregel bei Kunststoff Tiefziehteilen bei Stapelung: Stapeltechnik\u003C/span>\u003C/h2>\u003Cp>Wenn Ihr Tiefziehteil gestapelt werden soll, muss das schon frühzeitig in der Konstruktion beachtet werden, sodass für die Stapelung Platz gelassen wird. Bei der Selektion der passenden \u003Ca href=\"https://www.formary.de/blog/transportschaeden-vermeiden-mithilfe-dieser-4-stapeltechniken\">Stapeltechnik\u003C/a> entscheiden verschiedene Punkte:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Materialausgangsstärke\u003C/span>\u003C/h3>\u003Cp>Die Wahl der Stapelung eines Tiefziehteils hängt in erster Linie von der Steifigkeit des Tiefziehteils und den Gleiteigenschaften des Materials ab. Je dicker das Material (oft bei Mehrwegtrays der Fall), desto besser lässt sich stapeln. Je schlechter die Gleiteigenschaften des Materials, desto besser die Haftreibung, und desto besser lässt sich dadurch stapeln.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Sensibilität der Produkte\u003C/span>\u003C/h3>\u003Cp>Wenn nicht über die Bauteile gestapelt werden darf (oder soll), sondern einige mm Luft eingehalten werden, wird eine hochwertigere Stapeltechnik benötigt. Der Grund ist, dass die Stapelung des Tiefziehteils selbsttragend ist, d.h. das Gewicht der Trays und des Inhalts ohne zusätzliche Abstützungen auf der Trayfläche tragen muss.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Dringlichkeit des Zeitplans\u003C/span>\u003C/h3>\u003Cp>Komplexe Stapeltechniken mit beweglichen Stapelelementen setzen die Fertigung aus einem Klappenwerkzeug voraus. Die Herstellung eines solchen Werkzeugs ist zeitintensiver als ein relativ einfach gehaltenes Hinterschnittstapelungs-Werkzeug.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">12. Gestaltungsregel bei Kunststoff Tiefziehteilen: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Materialauswahl\u003C/span>\u003C/h2>\u003Cp>Weichere Kunststoffe haben nach der Entformung \u003Cstrong>größere Rückverformungen\u003C/strong> und höhere Verarbeitungsschwindungen. \u003Ca href=\"https://www.formary.de/materialien\">Materialien\u003C/a> mit hoher Härte und Steifigkeit sind automatisch in einer besseren Toleranzgruppe in puncto Genauigkeit.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\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 Mehr zu Kunststoffen, ihren Eigenschaften und deren Einfluss auf die Gesamtkosten im Tiefziehen, können Sie in unserem Whitepaper \u003Ca href=\"https://www.formary.de/whitepaper-ebooks/materialleitfaden-fuer-kunststoff-tiefziehteile\">“Materialleitfaden für Kunststoff Tiefziehteile”\u003C/a> nachlesen. \n    \u003C/p>\u003C/div>\u003Ca>\n\u003C/a>\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">13. Zusatztipp: \u003C/span>\u003Cspan style=\"color:#00a9a5;\">Optimal gesetzte Gravuren\u003C/span>\u003C/h2>\u003Cfigure class=\"image image-style-align-right image_resized\" style=\"width:36.72%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Gravuren_bei_Kunstsoff_Tiefziehteilen_9998ef3f99.png\" alt=\"Gravuren bei Kunstsoff Tiefziehteilen\">\u003C/figure>\u003Cp>Sollten Sie Kennzeichnungen im Tiefziehteil benötigen, können Sie diese gerne direkt mit einer Gravur in das Werkzeug einbringen.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Kosten der Gravur\u003C/span>\u003C/h3>\u003Cp>Die Kosten der Gravur können sehr unterschiedlich ausfallen, je nachdem, wie diese eingebracht werden muss. Als Faustregel gilt: Eine negativ (versenkt) eingebrachte Gravur ist relativ kostengünstig, eine positiv eingebrachte (erhabene) Gravur deutlich aufwendiger, und daher teurer.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Häufige Fragen zur Konstruktion von Kunststoff Tiefziehteilen\u003C/span>\u003C/h2>\u003Ch4>\u003Cspan style=\"color:#005250;\">Warum sind Radien wichtig?\u003C/span>\u003C/h4>\u003Cp>Radien erleichtern das Tiefziehen, verhindern Risse und Falten. Mindestradius: 1,5 mm, bei scharfen Kanten mindestens die Materialstärke.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Was sind Wandschrägen und warum werden sie benötigt?\u003C/span>\u003C/h4>\u003Cp>Wandschrägen (mind. 2°) erleichtern die Entformung und verhindern Oberflächenmarkierungen. Standard: Negativwerkzeuge 1,5–2°, Positivwerkzeuge 4–6°.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Positiv- oder Negativformung: worin liegt der Unterschied?\u003C/span>\u003C/h4>\u003Cp>Positivteile dünnen am Rand aus, Negativteile am Boden. Positivformen sind meist vorteilhafter in Bezug auf Streckverhältnis und Materialschwächen.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Warum sollten Übergänge und Hinterschnitte berücksichtigt werden?\u003C/span>\u003C/h4>\u003Cp>Sanfte Übergänge verhindern Falten und Aufrisse. Hinterschnitte erschweren die Entformung und sollten reduziert oder konstruktiv angepasst werden.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Welche Rolle spielt die Materialauswahl und Schwindung?\u003C/span>\u003C/h4>\u003Cp>Weiche Kunststoffe schrumpfen stärker und verformen sich nach der Entformung. Härtere Materialien bieten höhere Maßhaltigkeit und bessere Toleranzen.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Was sollte man bei Gravuren und Befestigungspunkten beachten?\u003C/span>\u003C/h4>\u003Cp>Gravuren: negativ (versenkt) sind günstiger, positiv (erhaben) sind teurer. Befestigungspunkte wie Schrauben oder Nieten sollten früh geplant werden, abhängig von Belastung und Nutzung.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Kunststoffteile konstruieren - Ganz einfach mit unseren Konstruktionstipps\u003C/span>\u003C/h2>\u003Cp>Durch das Beachten dieser Design-Grundregeln können potenzielle Fehlerquellen im Endprodukt schon beim Erstellen der CAD-Daten mit einbezogen und proaktiv umgangen werden. So können Sie mit Ihrem Produkt direkt in das \u003Ca href=\"https://www.formary.de/prototypen\">Prototyping\u003C/a> gehen.\u003C/p>\u003Cp>Sie haben weitere Fragen? Dann kontaktieren Sie uns oder laden sich für weitere Informationen zum Kunststoff Thermoforming unseren \u003Ca href=\"https://www.formary.de/design-guide\">Design-Guide\u003C/a> herunter.\u003C/p>","gestaltungsregeln-bei-kunststoff-tiefziehteilen",{"id":707,"documentId":708,"createdAt":709,"updatedAt":710,"publishedAt":711,"locale":10,"title":712,"introduction":713,"content":714,"slug":715,"cover":1138,"seo":1188,"blog_author":1202,"blogcategory":1210,"inline_hubspot_form":85,"blocks":1248,"localizations":1249},{"id":1139,"documentId":1140,"name":1141,"alternativeText":712,"caption":16,"width":367,"height":361,"formats":1142,"hash":1183,"ext":150,"mime":153,"size":1184,"url":1185,"previewUrl":85,"provider":209,"provider_metadata":85,"createdAt":1186,"updatedAt":1186,"publishedAt":1187},2078,"dkdy1x18tz5dlnvewc8dwpq0","Construction Data in Thermoforming: These Factors Must Be Considered for Plastic Deep Drawn Parts Banner 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im Thermoforming: Diese Faktoren sind bei Kunststoff Tiefziehteilen zu beachten","Tiefziehteile sind kundenspezifisch und werden individuell in einem CAD-Format konstruiert. Bevor ein Tiefziehwerkzeug gefertigt wird, erfolgt ein kundenseitiger Freigabeprozess der CAD Daten, bzw. der daraus abgeleiteten, bemaßten PDF Zeichnung. ","\u003Ch2>\u003Cspan style=\"color:#005250;\">Konstruktiondaten im Thermoforming - Das Wichtigste in Kürze\u003C/span>\u003C/h2>\u003Cul>\u003Cli>\u003Cstrong>Präzision der Konstruktionsdaten:\u003C/strong> Maße, Material, Materialstärke, Wandschrägen und Radien müssen genau geprüft werden, um Funktionalität, Qualität und Design des Tiefziehteils sicherzustellen.\u003C/li>\u003Cli>\u003Cstrong>Nestergeometrie & Verbausituation:\u003C/strong> Bauteile müssen für Transport, Montage und Integration ins Gesamtprodukt optimal gestaltet sein. Die Toleranzen und Packdichte sind entscheidend.\u003C/li>\u003Cli>\u003Cstrong>Prozess & Datenformate:\u003C/strong> CAD-Daten (STEP für 3D, PDF für 2D) werden erstellt, geprüft, freigegeben und bemustert, bevor die Serienproduktion startet (Zeitrahmen ca. 3–5 Wochen).\u003C/li>\u003C/ul>\u003Cp>Dieser Beitrag erläutert den Erstellungs- und Freigabeprozess der Konstruktionsdaten eines Kunststoff Tiefziehteils und hebt die wichtigsten Faktoren hervor, die auf Kundenseite bei der Freigabe wichtig sind.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Was sind Konstruktionsdaten?\u003C/span>\u003C/h2>\u003Cp>Wenn im \u003Ca href=\"https://www.formary.de/tiefziehen-kunststoff\">Kunststoff Tiefziehen\u003C/a> von Konstruktionsdaten gesprochen wird, ist die CAD \u003Cstrong>(Computer-Aided-Design)\u003C/strong>-Datei oder die davon abgeleitete, bemaßte Zeichnung (oft im PDF Format) des fertigen Endprodukts, hier also das Tiefziehteil, gemeint.\u003C/p>\u003Cp>Bei der Erstellung der Daten fließen sowohl Kundenanforderungen als auch Design for Manufacturing (DfM) Empfehlungen auf Tiefzieher- oder Werkzeugbauer-Seite ein.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Typische Parameter im Thermoforming\u003C/span>\u003C/h3>\u003Cul>\u003Cli>Längenmaße\u003C/li>\u003Cli>Nestergeometrien\u003C/li>\u003Cli>Materialstärken\u003C/li>\u003Cli>Verbausituationen\u003C/li>\u003Cli>Aussparungen für spätere Bearbeitung\u003C/li>\u003Cli>Radien und Wandschrägen für Tiefziehbarkeit\u003C/li>\u003C/ul>\u003Cp>Die Konstruktion des Kunststoff Tiefziehteils dient als Grundlage für die Erstellung des \u003Ca href=\"https://www.formary.de/blog/tiefziehwerkzeug-fuer-kunststoff-tiefziehteile\">Tiefziehwerkzeugs\u003C/a> aus Aluminium. Wenn das Werkzeug erstellt ist, erfolgt im nächsten Schritt die Musterfreigabe.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Kundenanforderungen bei Konstruktionsdaten\u003C/span>\u003C/h2>\u003Cp>Meist entwickelt formary auf Basis der Kundenanforderungen das Produkt und ergo die Konstruktionsdaten komplett auf der grünen Wiese. Manchmal stellen Kunden jedoch auch bereits fertige CAD Daten des Tiefziehteils zur Verfügung. Dies geschieht entweder, wenn das Kunststoff Tiefziehteil schon im Unternehmen existiert und neu angefragt wird oder die interne Konstruktionsabteilung einen Vorschlag erstellt hat.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Prozess bei bestehenden CAD-Daten\u003C/span>\u003C/h3>\u003Col>\u003Cli>Prüfung auf \u003Ca href=\"https://www.formary.de/blog/design-for-manufacturing\">Design for Manufacturability (DfM)\u003C/a>\u003C/li>\u003Cli>Anpassung auf Tiefziehbarkeit\u003C/li>\u003Cli>Kundenprüfung auf Vollständigkeit und Richtigkeit\u003C/li>\u003C/ol>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/formary_Konfigurator_Dritter_Schritt_0072873921.png\" alt=\"Produktangaben im Konfigurator\">\u003Cfigcaption>Ausschnitt aus dem formary Konfigurator\u003C/figcaption>\u003C/figure>\u003Ch2>\u003Cspan style=\"color:#005250;\">Welches Format sollten Ihre Konstruktionsdaten haben?\u003C/span>\u003C/h2>\u003Cp>Die Konstruktionsdaten werden Kunden bei formary immer in Form von 2D-Zeichnungen im PDF-Format und 3D-Daten im STEP-Format zur Verfügung gestellt.\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Was bedeutet STEP?\u003C/span>\u003C/h3>\u003Cp>STEP (\u003Cstrong>St\u003C/strong>andard for the \u003Cstrong>E\u003C/strong>xchange of \u003Cstrong>P\u003C/strong>roduct model data) ist ein Dateityp, das den Austausch von 3D-Modellen zwischen CAD-Systemen, unabhängig davon, auf welchem System das Modell erstellt wurde, ermöglicht.\u003C/p>\u003Cp>Die technische Zeichnung enthält detaillierte Informationen über:\u003C/p>\u003Cul>\u003Cli>Texturen\u003C/li>\u003Cli>Toleranzen\u003C/li>\u003Cli>Materialeigenschaften\u003C/li>\u003C/ul>\u003Cp>Die präzise und sorgfältige Prüfung der Konstruktionsdaten ist relevant, um sicherzustellen, dass die thermogeformten Teile den gewünschten Anforderungen bezüglich Funktionalität, Qualität und Design entsprechen.\u003C/p>\u003Ch2>\u003Cspan style=\"color:#005250;\">Die wichtigsten Faktoren bei der Prüfung von Konstruktionsdaten zur Freigabe\u003C/span>\u003C/h2>\u003Cp>Um sicherzustellen, dass die erstellte Tiefzieh-Konstruktion den Anforderungen entspricht und die Funktionalität gewährleistet ist, müssen folgende Faktoren sorgfältig berücksichtigt werden:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">Maße\u003C/span>\u003C/h3>\u003Cp>Die toleranzgenaue Einhaltung der Längenmaße (z.B. Länge x Breite x Höhe) ist immer relevant, um sicherzustellen, dass das Endprodukt die gewünschten Spezifikationen erfüllt. Dabei sollte geprüft werden, ob die Konstruktionsdaten maßhaltig nach der besprochenen DIN ISO 2768 Längenmaßnorm erstellt wurden.\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/Tiefzieh_Abdeckung_Abmessungen_26cbd7985c_1_46c01ef13b.jpg\" alt=\"Abmaße des Tiefzieh-Werkzeugs\">\u003Cfigcaption>Bauteilmaße Länge x Breite x Höhe\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Nestergeometrie\u003C/span>\u003C/h3>\u003Cp>Die \u003Ca href=\"https://www.formary.de/blog/so-bestimmen-sie-die-geeigneten-formnester-ihres-werkstuecktraegers-1\">Nestergeometrie \u003C/a>ist insbesondere bei \u003Ca href=\"https://www.formary.de/loesungen/kunststofftray-lagerung-transport\">Kunststofftrays \u003C/a>ausschlaggebend. Konstruktionsdaten sollten klar dokumentieren:\u003C/p>\u003Cul>\u003Cli>Werden die Bauteile in besprochener Ausrichtung eingelegt?\u003C/li>\u003Cli>Werden die Bauteile an der gewünschten Geometrie aufgenommen, um sicher auf dem geplanten Transportweg (Werk, Straße oder Schiene) befördert zu werden?\u003C/li>\u003Cli>Sind Griffmulden zur Entnahme gewünscht und vorhanden?\u003C/li>\u003Cli>Ist die Packdichte wie besprochen?\u003C/li>\u003C/ul>\u003Cp>Die Konstruktionsdaten sollten demnach klare Angaben zu den Randbedingungen und Toleranzen enthalten, die für die Nestergeometrie der Kunststoff Tiefziehteile gelten. Dies bedeutet, dass die Teile so konstruiert werden sollten, dass sie den verfügbaren Raum optimal ausnutzen und gleichzeitig einen reibungslosen Produktionsablauf ermöglichen.\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/sm_0068_bit_003_formary_50028_transport_5a6906c90d_1_41d10960f4.jpg\" alt=\"Nestergeometrie des Tiefziehteils\">\u003Cfigcaption>Tiefziehtray mit formangepassten Nestern\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Verbausituation\u003C/span>\u003C/h3>\u003Cp>\u003Ca href=\"https://www.formary.de/loesungen/kunststoff-abdeckungen-gehaeuse\">Abdeckungen\u003C/a> erfordern konkrete Daten zur Verbausituation. Die Verbausituation bezieht sich auf die Integration des thermoformten Teils in das Gesamtprodukt oder die Gesamtbaugruppe des Kundenprodukts. Diese ist wichtig, um sicherzustellen, dass das Teil problemlos in die vorgesehene Umgebung passt und alle Montageanforderungen erfüllt. Daher ist zu prüfen:\u003C/p>\u003Cul>\u003Cli>Stimmen die Maße an Befestigungs- und Anbaupunkten mit den Spezifikationen überein?\u003C/li>\u003Cli>Sind Toleranzen für die Montage berücksichtigt?\u003C/li>\u003Cli>Ist die Kompatibilität mit anderen Komponenten gesichert?\u003C/li>\u003C/ul>\u003Cfigure class=\"image image-style-align-center image_resized\" style=\"width:50%;\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/sm_0024_bit_003_formary_50200_abdeckung_084035d392_1_92852eb019.jpg\" alt=\"Verbausituation der Tiefziehteile\">\u003Cfigcaption>Tiefgezogene Kunststoffabdeckungen\u003C/figcaption>\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">Material\u003C/span>\u003C/h3>\u003Cp>Verschiedene Kunststoffe haben unterschiedliche Eigenschaften und eignen sich für unterschiedliche Anwendungen. Das auf der Zeichnung spezifizierte Material sollte demnach auf Korrektheit geprüft werden.\u003C/p>\u003Ch4>\u003Cspan style=\"color:#005250;\">Wichtige Materialeigenschaften\u003C/span>\u003C/h4>\u003Cul>\u003Cli>Temperaturbeständigkeit\u003C/li>\u003Cli>Härte\u003C/li>\u003Cli>UV-Schutz\u003C/li>\u003Cli>ESD-Schutz\u003C/li>\u003Cli>Chemische Beständigkeit\u003C/li>\u003C/ul>\u003Cp>Mehr Informationen zu Kunststoffen finden Sie in \u003Ca href=\"https://www.formary.de/materialien\">Materialien\u003C/a>.\u003C/p>\u003Cfigure class=\"image image-style-align-center\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/md_kunststoff_granulat_9b0e2d4096_1_267ca762c0.jfif\" alt=\"Material und Materialausgangsstärke\">\u003Cfigcaption>Kunststoffgranulat\u003C/figcaption>\u003C/figure>\u003Ch4>\u003Cspan style=\"color:#005250;\">Materialausgangsstärke\u003C/span>\u003C/h4>\u003Cp>Die Materialausgangsstärke bezieht sich auf die Dicke der \u003Ca href=\"https://www.formary.de/plattenfertigung\">Kunststoffplatte \u003C/a>oder \u003Ca href=\"https://www.formary.de/rollenfertigung\">-rolle,\u003C/a> welche beim Thermoforming verwendet wird. Die Materialausgangsstärke wurde während der Erstellung des Angebots auf Basis technischer Kriterien festgelegt und kann daher mit diesem abgeglichen werden.\u003C/p>\u003Cp>Werden mehrere Ausgangsstärken bemustert, um das optimale Stabilitäts- und Geometrieergebnis zu erzielen, wird die finale Konstruktionszeichnung entsprechend auf die gewählte Lösung aktualisiert.\u003C/p>\u003Cdiv class=\"raw-html-embed\">\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 Welche Gestaltungsregeln es bei der Konstruktion von Tiefziehteilen zu beachten gilt, lesen Sie im Beitrag  \u003Ca href=\"https://www.formary.de/blog/gestaltungsregeln-bei-kunststoff-tiefziehteilen\">“Gestaltungsregeln bei Kunststoff Tiefziehteilen.”\u003C/a>\u003C/p>\n    \u003C/div>\u003C/div>\u003Ch2>\u003Cspan style=\"color:#005250;\">Der Prozessablauf zur Erstellung und Überprüfung der Konstruktionsdaten bei formary\u003C/span>\u003C/h2>\u003Cp>Für die Erstellung und Überprüfung von Konstruktionsdaten sieht der Prozess folgendermaßen aus: \u003Cstrong>Anforderungen - Konstruktion - Datenfreigabe - Muster - Musterfreigabe - Serie.\u003C/strong>\u003C/p>\u003Cp>Im Detail verläuft die \u003Ca href=\"https://www.formary.de/blog/projektplanung-im-thermoforming\">Projektplanung im Thermoforming\u003C/a> grob unterteilt in folgenden Schritten:\u003C/p>\u003Ch3>\u003Cspan style=\"color:#005250;\">1. Fragen Sie Ihr Projekt an\u003C/span>\u003C/h3>\u003Cp>Tragen Sie ihre Anforderungen im Konfigurator ein und schicken formary Ihre Anfrage ab. Innerhalb von 24 Stunden erhalten Sie ein Angebot.\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Tiefziehteil_anfragen_Laptop_Mockup_2b60f6315d.png\" alt=\"Projektanfrage\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">2. Lassen Sie uns Ihre Daten erstellen\u003C/span>\u003C/h3>\u003Cp>Im zweiten Schritt stehen Ihnen zwei Optionen zur Verfügung:\u003C/p>\u003Cul>\u003Cli>Sie haben eine Konstruktionsabteilung?\u003Cul>\u003Cli>Dann erstellen Sie gerne selbst Ihr Kunststoff Tiefziehteil. Gerne können Sie unseren Guide für die relevanten Stellen des tiefziehfähigen Designs zu Rate ziehen. Wir überprüfen die Zeichnung im Anschluss und passen diese auf Tiefziehfähigkeit an.\u003C/li>\u003C/ul>\u003C/li>\u003Cli>Sie wollen sich von Anfang an Ihr Tiefziehteil aus Kunststoff von Konstrukteuren mit langjähriger Erfahrung in allen Anwendungsbereichen konstruieren lassen?\u003Cul>\u003Cli>formary erstellt Ihre Daten und konstruiert nach Ihren Anforderungen optimale Geometrien zum Thermoformen.\u003C/li>\u003C/ul>\u003C/li>\u003C/ul>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Datenfreigabe_Laptop_Mockup_und_Konstruktion_8347a0859b.png\" alt=\"Datenerstellung\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">3. Erhalten Sie schnell Ihr Muster\u003C/span>\u003C/h3>\u003Cp>Abhängig von Ihrem Zeitplan erhalten Sie Muster aus der entsprechend passenden Option. Es bieten sich 4 Optionen an, abhängig vom Sinn und Zweck der Muster:\u003C/p>\u003Cul>\u003Cli>Muster aus 3D-Druck-Werkzeug\u003C/li>\u003Cli>Muster aus Ureol-Werkzeug\u003C/li>\u003Cli>Muster aus Teilsegment Serien-Werkzeug\u003C/li>\u003Cli>Muster aus Serien-Werkzeug\u003C/li>\u003C/ul>\u003Cp>Mehr zu den Vorteilen, Nachteilen und Einsatzbereichen der unterschiedlichen Muster finden Sie bei \u003Ca href=\"https://www.formary.de/prototypen\">Prototypen\u003C/a> und unserem Blogbeitrag zum Thema \u003Ca href=\"https://www.formary.de/blog/rapid-prototyping-moeglichkeiten-im-tiefziehen\">Rapid Prototyping.\u003C/a>\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Werkzeug_und_Bemusterung_cd0eff947f.png\" alt=\"Muster erhalten\">\u003C/figure>\u003Ch3>\u003Cspan style=\"color:#005250;\">4. Wir starten mir Ihrer Serienproduktion\u003C/span>\u003C/h3>\u003Cp>Nach erfolgreicher Bemusterung starten wir mit der Serienproduktion. Abhängig von Ihrem Material, der gewählten Werkzeugausführung, der Maschinenart zur Fertigung sowie der Stückzahl, beträgt die Vorlaufzeit in etwa \u003Cstrong>3-5 Wochen\u003C/strong> von Freigabe/Bestellungseingang bis zur Auslieferung Ihrer Serie.\u003C/p>\u003Cfigure class=\"image\">\u003Cimg src=\"https://fsn1.your-objectstorage.com/formary-de-production-cms/Serienfertigung_ede6049265.png\" alt=\"Serienproduktion starten\">\u003C/figure>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Häufige Fragen zu Konstruktionsdaten im Thermoforming\u003C/span>\u003C/h2>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Was sind Konstruktionsdaten im Thermoforming?\u003C/span>\u003C/h4>\u003Cp>Konstruktionsdaten beziehen sich auf die CAD-Dateien oder die abgeleiteten, bemaßten Zeichnungen des Tiefziehteils. Sie enthalten alle Informationen, die für die Fertigung, Bemusterung und Serienproduktion benötigt werden, z. B. Maße, Material, Radien, Wandschrägen, Nestergeometrien und Verbausituationen.\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Welche Formate werden für Konstruktionsdaten verwendet?\u003C/span>\u003C/h4>\u003Cul>\u003Cli>\u003Cstrong>3D-Daten:\u003C/strong> STEP-Format (für den plattformunabhängigen Austausch von 3D-Modellen)\u003C/li>\u003Cli>\u003Cstrong>2D-Zeichnungen:\u003C/strong> PDF (mit allen Maßen, Toleranzen, Materialangaben und Texturen)\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Warum ist die Materialausgangsstärke wichtig?\u003C/span>\u003C/h4>\u003Cp>Die Materialausgangsstärke beschreibt die Dicke der Kunststoffplatte oder -rolle, die beim Thermoforming verwendet wird. Sie beeinflusst Stabilität, Geometrie und Verformbarkeit des Teils. Unterschiedliche Ausgangsstärken können bemustert werden, um das optimale Ergebnis zu erzielen.\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Welche Faktoren müssen bei der Freigabe von Konstruktionsdaten geprüft werden?\u003C/span>\u003C/h4>\u003Cul>\u003Cli>\u003Cstrong>Maße:\u003C/strong> Längen, Breiten, Höhen und Toleranzen gemäß DIN ISO 2768\u003C/li>\u003Cli>\u003Cstrong>Nestergeometrie:\u003C/strong> Optimale Ausrichtung für Transport, Montage und Lagerung\u003C/li>\u003Cli>\u003Cstrong>Verbausituation:\u003C/strong> Passgenauigkeit des Teils in der Gesamtbaugruppe\u003C/li>\u003Cli>\u003Cstrong>Material & Eigenschaften:\u003C/strong> Temperaturbeständigkeit, Härte, UV- und ESD-Schutz, chemische Beständigkeit\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Was versteht man unter Nestergeometrie?\u003C/span>\u003C/h4>\u003Cp>Die Nestergeometrie definiert, wie Bauteile in Trays oder Behältern platziert werden. Sie ist wichtig für sicheren Transport, einfache Entnahme und optimale Packdichte.\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Wie läuft der Prozess zur Erstellung und Freigabe von Konstruktionsdaten ab?\u003C/span>\u003C/h4>\u003Col>\u003Cli>Anfrage im Konfigurator stellen\u003C/li>\u003Cli>Erstellung der Konstruktionsdaten (entweder durch den Kunden oder durch formary)\u003C/li>\u003Cli>Prüfung und Freigabe der Daten durch den Kunden\u003C/li>\u003Cli>Bemusterung (verschiedene Musteroptionen möglich)\u003C/li>\u003Cli>Start der Serienproduktion\u003C/li>\u003C/ol>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Welche Optionen gibt es für Muster?\u003C/span>\u003C/h4>\u003Cul>\u003Cli>3D-Druck-Werkzeug\u003C/li>\u003Cli>Ureol-Werkzeug\u003C/li>\u003Cli>Teilsegment Serien-Werkzeug\u003C/li>\u003Cli>Serien-Werkzeug\u003C/li>\u003C/ul>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Wie lange dauert die Serienproduktion?\u003C/span>\u003C/h4>\u003Cp>Ab Freigabe/Bestellung beträgt die Vorlaufzeit je nach Material, Werkzeug und Stückzahl etwa \u003Cstrong>3–5 Wochen\u003C/strong>.\u003C/p>\u003Ch4>\u003Cspan style=\"color:hsl(0,0%,0%);\">Was ist der Vorteil der kundenseitigen Prüfung der Konstruktionsdaten?\u003C/span>\u003C/h4>\u003Cp>Die Prüfung ermöglicht es, fehlende oder übersehene Anforderungen frühzeitig zu erkennen und anzupassen, wodurch Bemusterung und Serienproduktion effizienter und fehlerfrei verlaufen.\u003C/p>\u003Chr>\u003Ch2>\u003Cspan style=\"color:#005250;\">Fazit: Qualitätssicherung im Thermoforming durch genaue Prüfung der Konstruktionsdaten\u003C/span>\u003C/h2>\u003Cp>Konstruktionsdaten des Thermoformteils werden also nicht nur zur Herstellung des Werkzeugs erstellt, sondern vor allem auch für die kundenseitige Prüfung des Endprodukts. In diesem Stadium können etwaige hinzugekommene oder bisher übersehene Anforderungen einfach erkannt und dazu konstruiert werden. Dies gewährleistet einen effizienten Bemusterungs- und Projektprozess. \u003C/p>\u003Cp>formary sorgt dafür, dass Ihnen während des gesamten Projekts ein kompetenter Ansprechpartner zur Verfügung steht, um Fragen zu klären. Testen Sie es jetzt selbst aus und fragen Sie Ihr Kunststoff Tiefziehteil digital an. Jetzt \u003Ca href=\"https://www.formary.de/konfigurator\">konfigurieren.\u003C/a>\u003C/p>","freigabe-von-konstruktionsdaten-welche-faktoren-sind-bei-kunststoff-tiefziehteilen-zu-beachten",{"__component":1259,"id":1260,"title":1261},"page-template.newsletter",363,"Don't miss any important tips and news about thermoformed parts.",[1263],{"id":124,"documentId":133,"createdAt":1264,"updatedAt":1265,"publishedAt":1266,"locale":128},"2026-01-08T22:53:05.234Z","2026-01-16T15:54:40.886Z","2026-01-16T15:54:41.252Z",{},["Reactive",460]]