Vacuum thermoforming is one of the most commonly used forming methods for plastic packaging containers. It is a secondary forming process that uses thermoplastic sheets as the workpiece. Abroad, vacuum thermoforming is an age-old technique; through continuous innovation and refinement, it has now evolved to feature high levels of automation and mechanization, zero waste generation, 100% conversion of raw and auxiliary materials into finished products, and full‑line production. Thick-sheet thermoforming Now, let’s take a look at the applications of thick-sheet thermoforming in the automotive components industry!

　　Introduction to Thick-Section Thermoforming

　　In the thick-sheet thermoforming process, products can be categorized into two types—thick-walled and thin-walled—based on the form of the raw material (sheet or roll). Thick-sheet thermoforming refers to applications where the raw material thickness exceeds 2 mm; such parts cannot be produced using fully automated blister‑forming equipment and must be manufactured on semi‑automatic blister‑forming machines specifically designed for thick‑walled sheets.

　　 Thick-sheet thermoforming Products typically feature large surface areas, substantial heights, and thick material thicknesses. The manufacturing processes for both thick‑sheet thermoforming and thin‑wall thermoformed molds are essentially the same, with vacuum thermoforming being the predominant method. These plastic products are widely used across numerous sectors of everyday life, including automotive interior and exterior components, transportation, construction materials, packaging, medical devices, household appliances, stationery and sanitary ware, and sporting goods.

　　The principle of thick-sheet thermoforming is essentially the same as that of conventional blister packaging: plastic sheets are cut to specified dimensions, heated to soften them, and then deformed under differential air pressure or mechanical force on both sides. The formed sheet is subsequently pressed against the contour of a dedicated mold, cooled, and trimmed as it is cut.

　　The commonly used raw sheet materials for thick‑sheet thermoforming include HDPE, ABS, and ABS/TPU. Below is a brief overview of the key characteristics of these three materials.

　　1) HDPE (high-density polyethylene) material exhibits heat resistance, cold resistance, chemical stability, high rigidity, toughness, and excellent resistance to environmental stress cracking. Main applications include: 200-liter drums, tanks, pallets, components, yachts, blister tray lids, and specialized packaging for most automotive parts, among others.

　　2) ABS (acrylonitrile–butadiene–styrene) material: exhibits excellent impact resistance, heat resistance, low‑temperature resistance, chemical resistance, and electrical properties; it is easily processed into HDPE‑like grades, offering stable product dimensions, good surface gloss, and superior load‑bearing capacity. However, in terms of low‑temperature performance, toughness, and resistance to environmental stress cracking, HDPE remains advantageous. Main applications: widely used in the automotive, electronics and electrical, office equipment, and telecommunications sectors. In the packaging field, it is primarily employed for automated pick‑and‑place operations that demand high dimensional accuracy.

　　3) ABS (TPU thermoplastic polyurethane) material: This is a new type of sheet that builds on the conventional ABS sheet‑making process by incorporating a specialized co‑extrusion technique, resulting in a TPU film coating on the ABS surface. Products made from this material combine ABS’s excellent mechanical properties with TPU’s superior wear resistance and tear strength; however, its cost is 2–3 times that of standard materials. Due to these higher costs, its applications are somewhat limited. TPU characteristics: Wear resistance is critical because materials often endure friction, abrasion, and impact during use, leading to gradual surface degradation. TPU exhibits outstanding wear resistance—more than five times that of natural rubber—and is therefore a preferred choice for wear‑resistant components. In addition, TPU boasts exceptional tear strength, far surpassing that of most conventional plastics. Main applications: Primarily used in automotive interior parts, and in packaging for components with stringent cleanliness requirements, such as engine and transmission parts, as well as other powertrain components.

　　The above is what has been introduced. Thick-sheet thermoforming For more information on the application of manufacturing processes in the automotive components industry, please feel free to contact us at any time!