Thermoforming Plastic: Today’s Solution for OEMs

Energy, the economy and global competition present added burden for OEMs, and many find their solutions at SAY Plastics. Product manufacturers use thermoformed plastics to reduce costs, enhance appearance, increase durability, and provide long-lasting benefits over the life of the product. From parts as small as 6 square inches to those as large as 5’ x 7’ and 36” deep draw, many designs are achievable within our thermoforming capacity.

Cost Saving Benefits with Thermoforming

    • Parts Consolidation. Thermoforming makes it possible to consolidate parts and reduce assembly costs.
    • Eliminate Paint. Thermoformed plastics are available in a wide range of colors and textures. If painting is required, most thermoformed plastics offer good paint adhesion.
    • Lower Tooling Costs. Thermoforming tooling costs are less than most other parts supply options.
    • Cost Efficient. Thermoforming can generate large plastic parts at a lower overall cost than steel, aluminum, or fiberglass reinforced plastic.
    • Durable. Thermoformed plastics are more durable than alternative materials, reducing warranty and replacement costs.
    • Machinable. Thermoformed plastic is readily and cleanly machined if necessary, for adding holes and cutouts with a smooth edge.

Performance Benefits with Thermoforming

thermoforming plastic

  • Design Flexibility. Manufacturers enjoy greater design flexibility and more styling options with thermoformed plastic parts.
  • Material Optimization. Because thermoforming can use co-extruded materials, many custom options are possible – high-gloss surfaces, textured finishes, added rigidity, scratch resistance, and soft-feel lamination.
  • Corrosion Resistance. Plastic parts resist corrosion and perform well in varying temperatures.
  • Assembly Values. Thermoplastics are compatible to adhesive bonding, welding or hardware application.
  • High Impact Resistance. Studies show plastics have good impact resistance, and with proper design can absorb up to twelve times more crash energy than steel – resulting in dent resistance and resilience.
  • Quick Turnaround. Thermoforming can cut lead times for design, processing and assembly. The SAYtooling System expedites start-up production.
  • Reduced Weight. Thermoformed plastic parts are lightweight, offering significantly reduced part weight – up to 30-40% – when compared to steel or fiberglass.

Environmental Benefits with Thermoforming

  • Recyclable. Today’s thermoplastics are recyclable while thermosets (FRP, RIM and SMC) are not.
  • Fuel Savings. The use of plastic parts in vehicle manufacturing produces fuel savings without compromising safety. Energy studies show that reducing vehicle weight by 10% can increase fuel economy by 5-7%.