Frequently Asked Questions
What is Thermoforming?
Thermoforming is a manufacturing process that involves heating flat plastic sheets or rolls until they become pliable, then forming them into specific shapes using a mold and pressure or vacuum. Once cooled, the plastic retains its new shape. A secondary trimming process is often used to achieve the final dimensions and design. Any excess material is reground and recycled to minimize waste.
What is the difference between vacuum forming and pressure forming?
Both vacuum forming and pressure forming are types of thermoforming, where heated plastic sheets are shaped using a mold. The key difference lies in how the plastic is formed over the mold:
- Vacuum forming uses suction to pull the heated plastic sheet against the mold surface. It’s ideal for simpler shapes and high-volume production.
- Pressure forming combines vacuum suction with additional air pressure on the opposite side of the sheet, forcing the material more tightly against the mold. This allows for greater detail, sharper edges, and more complex designs—making it suitable for parts that require a more refined appearance.
What are the main benefits of Thermoforming?
Thermoforming offers several key advantages over other manufacturing processes. It allows for economical prototyping, lower tooling costs, and faster lead times, making it ideal for both product development and full-scale production. The process is highly efficient and cost-effective, and it enables the replacement of more expensive materials like glass, metal, or custom-fabricated parts with lightweight, durable plastic components—without sacrificing performance or quality.
What is the difference between thin and heavy gauge forming?
Thin gauge forming uses plastic ranging from 0.001″ to 0.060″ and is typically used for high-volume packaging applications such as blisters, clamshells, trays, and inserts. These parts are formed on high-speed, automated in-line machines and trimmed using hydraulic or roll die presses.
Heavy gauge forming, on the other hand, uses thicker plastic ranging from 0.060″ to 0.500″ and is ideal for durable, structural parts like P.O.P. displays, enclosures, housings, and panels. These components are formed on automated or hand-fed machines and typically CNC trimmed for precision and consistency.
Helmy Plastics has the in-house capability to produce both thin and heavy gauge thermoformed parts, offering versatility to meet a wide range of customer needs.
What types of plastic materials can you thermoform?
Helmy Plastics thermoforms a wide range of materials, including ABS, HIPS, PS, HDPE, HMWPE, PP, PET, PETG, and PVC. We also accommodate specialized requirements such as custom colors, textures, and finishes. Additionally, we can source materials that meet specific needs—such as FDA-approved grades for medical and food applications, electrostatic discharge (ESD) materials, and fire-retardant options.
What types of tooling are used in thermoforming?
Thermoforming typically uses three types of tooling:
- Machined Aluminum Molds – CNC-machined from CAD files, these precision molds offer tight tolerances and can be male or female. They are suitable for production use and can be mounted on temperature-controlled bases, with or without plug assist.
- Cast Aluminum Molds – Ideal for deep-draw parts, these molds are cast at a foundry using patterns created by Helmy from wood or composites. Like machined molds, they support temperature control and plug assists.
- Temporary Molds – Used for prototyping and short runs, these cost-effective molds are made from wood or composite materials. They’re ideal for evaluating fit, form, and function before final production.
What is the typical lead time for a project?
Helmy Plastics manages all processes in-house, allowing for efficient project timelines and quick turnarounds. Standard lead times range from 4 to 10 weeks, depending on project complexity, material availability, and customer requirements. While some projects are completed in as little as 2–4 weeks, others may involve extended collaboration over several months before entering production.
What are the typical stages of a project?
A thermoforming project at Helmy Plastics typically follows these key stages:
- Design – If a customer provides their own design files, we move directly to tooling. Otherwise, Helmy develops design concepts and 3D renderings based on the customer’s specifications. Once approved, detailed mold engineering drawings are created.
- Prototyping – When required, a prototype mold is produced to create sample parts for evaluating fit, form, and function. This stage also includes material selection, color matching, and necessary R&D.
- Tooling & Material Ordering – Once the prototype is approved, Helmy builds precision aluminum tooling along with forming and trimming fixtures. Custom materials are ordered according to tooling dimensions.
- Production – After material arrives, production begins. Initial runs may take longer due to machine setup and documentation, while repeat orders are processed more efficiently.
Shipping – Finished parts are shipped as a single delivery or stored for scheduled releases, based on customer needs
Why should I choose Helmy Plastics for my thermoforming needs?
At Helmy Plastics, design and engineering are at the core of everything we do. With over 20 years of experience specializing in high-quality, complex thermoforming, we bring expert craftsmanship, problem-solving, and precision to every project. We’re deeply committed to our customers’ success—because when you succeed, we succeed. From concept to completion, you can count on Helmy for reliable partnership, technical expertise, and custom solutions that deliver real results.
Maybe incorporate this somehow:
- 35 Years in Business
- Strong and Loyal Team. Average employment tenure is 10 years.
- Strong and Loyal Long Term Customer Base. Average customer tenure is over 10 years.
- Strong Safety Records and Lowest Unemployment Rate.
- Great Reputation, Great Quality, Great Service, Low to 0 rejection rates.
- Strategic Location.
- Large Facilities and In Place Equipment Ready for Scaling Up!
- Strong Skills for Two Plastic Processes Under One Roof, Thin Gauge and Heavy Gauge Thermoforming. Strong Skills Also For industrial design and CNC Machining and Tooling.
