Thick-Gauge Thermoforming: A Simple Guide by Om Raj Tech
What Is Thick Gauge Thermoforming?
At Om Raj Tech, we use thick-gauge thermoforming to create strong, durable plastic parts. In this process, a thick plastic sheet is heated until soft, then stretched over a mold. A vacuum removes air between the sheet and the mold, helping the material take the exact shape. Once cooled and trimmed, the part is ready for further finishing or assembly.
Why Thick Gauge Thermoforming Is Unique
What makes custom thick-gauge plastic thermoforming special is the option to use sheets up to half an inch thick. These sheets create large and strong parts—sometimes up to six by ten feet—making them suitable for heavy-duty applications. Because of their strength, these thermoformed parts are used for vehicle bodies, outdoor enclosures, guards, containers, machine covers, and many more demanding environments.
Benefits of Thick-Gauge Thermoforming
Thick gauge thermoforming is flexible, fast, and cost-friendly compared to other methods. It delivers parts with good looks, impact resistance, and chemical resistance. Another big advantage is that it allows much lower minimum order quantities than traditional molding methods, such as Injection Molding Solutions provided by various plastic injection molding manufacturers.
Thermoforming Tooling Options at Om Raj Tech
Different Tooling Materials We Use
Since thick-gauge thermoforming is a low-pressure process, tooling is simpler and far more affordable. Om Raj Tech builds tooling using:
Wood patterns
Composite
3D printed tools
Ceramic molds
Cast aluminum
Temperature-controlled aluminum
This variety helps us create tools for both small prototype batches and high-volume production runs.
Prototype Tools for Faster Development
Prototype tooling is one of the biggest advantages of this process. Wood, composite, and 3D printed tools can produce 1–10 prototype parts made from ABS, PVC, and blended materials. These tools are fast to build, usually within 1–4 weeks, depending on the design.
Production Tools for Stronger, Long-Term Use
For large production volumes, we use ceramic or aluminum tooling. These tools can last for thousands of production cycles. They usually require 8–12 weeks to build, depending on size, shape, and detailing.
Thick-Gauge Thermoforming Design Guidelines
Understanding Draw Ratio
The draw ratio helps determine if a part can be made efficiently. It compares the height of the part to its surface area. A safe and recommended draw ratio is around 2:1 for most geometries, though some parts may require special adjustments.
Importance of Draft Angles
Draft angles help parts release smoothly from the mold. A minimum of 3 degrees draft is recommended. Lower angles are possible, but they can increase part costs and startup time.
Final Part Thickness Matters
Since Om Raj Tech specializes in custom thick-gauge plastic thermoforming, the thickness and rigidity of the finished part play a big role in design decisions. The required material affects overall thickness, strength, and the tooling suggested by our team.
Choosing the Right Material
The final material choice depends on the part’s purpose, durability needs, environment, and chemical exposure. Our experts always help customers pick the best option for long-lasting performance.
Conclusion: Your Partner for Strong, Reliable Thermoformed Parts
Thick-gauge thermoforming is one of the most flexible and cost-effective processes for creating large, strong, and high-quality plastic parts. At Om Raj Tech, we combine advanced tools, expert design support, and a wide range of materials to deliver durable thermoformed components for all industries. Whether you're looking for prototypes or full production, our team is ready to help you get the best results.
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