Formex Manufacturing Inc. offers a competitive turnkey service for custom thermoformed plastic projects. Our services include design, tooling, forming, CNC trimming and additional secondaries. Besides conventional single sheet forming and twin sheet forming techniques, our specialty is twin sheet products with encapsulation features.

Design
Ideas, concepts, and final 2-D or 3-D files are successfully accomplished for your thermoformed plastic project by our team of experts specializing in reducing part cost without sacrificing effectiveness.

Tooling
Cast or machined aluminum molds with temperature control and optional blow and exhaust pins are designed to exact specifications required for your part. We work with a number of pattern makers, foundries, and machine shops to optimize quality and price.

Forming
Simultaneous Twin Sheet Pressure Forming - Two sheets of materials are heated with a three tier sandwich oven and formed at the exact same time on two different mold halves that have mating pinch line geometry. The opposing molds press together and internal vacuum sucks the plastic to the heated molds. At the same time blow pins propel inside the cavity and release 50 � 120 psi air pressure to ensure crisp part detail. The two halves of plastic are fused together at the pinch line with heat and pressure. The result is a single hollow body plastic part. The simultaneous process is effective with thinner gauge materials where the speed of material cooling too soon jeopardizes a quality bond.

Sequential Twin Sheet Pressure Forming � Same as above except the two sheets are heated in separate two tier sandwich ovens and the molds are formed in sequence one at a time. The sequential process is effective with thicker gauge materials which require a more efficient heating process.

Encapsulation � Used with either simultaneous or sequential twin sheet forming, a structure (wood, foam, metal, etc.) is inserted before the two mold halves press together. The result is a double wall part with localized internal reinforcement.

Single Sheet Pressure Forming � One sheet of material is formed on a mold with standard vacuum. In addition, a box is placed over the cavity and 50 � 120 psi is applied to force the material into all details of the mold.

Single Sheet Forming - One sheet of material is formed on a mold with standard vacuum. Plug assist, billow forming, or snap back techniques are used to manipulate material distribution.

CNC Trimming
Formed plastic parts are located on a vacuum fixture. A 5-axis 7.5 hp router travels around the part trimming out all perimeter run out and internal cut outs, holes, slots, and vents.

MULTI COMPONENT PROJECTS

TWIN SHEET PAD WITH EPS FOAM ENCAPSULATION

33" TALL SINGLE SHEET

HOLLOW TWIN SHEET