Design Considerations

Pressure Forming

Pressure forming is used when greater definition, variety of surface textures, small radii, and molded vents and pockets might be required. . Pressure forming is generally more expensive than vacuum forming, but tooling costs are only a fraction of the cost of other methods. …Read More

Vacuum Forming

This method is the most commonly used technique for forming plastic sheets into custom shapes. It is also the most economical method. …Read More

Twin Sheet

Twin-Sheet Pressure Forming is a process where 2 sheets are kept separate while heating, then brought together in a double female mold arrangement. A blow pipe is inserted between the 2 sheets and air pressure inflates them against the respective molds. Twin-sheet forming can produce a relatively flat, hollow part with injection molding cosmetics and strength and stiffness not available with straight pressure forming. …Read More


Tolerances will vary from part to part, depending on the materials, size, shape, number of cutouts and other configuration possibilities.

However, as a general rule of thumb, the following tolerances should apply. …Read More

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