414-351-1000 / Toll Free: 888-611-0270 sales@genplas.com

Advantages of Converting Metal to Thermoformed Plastics

Upgrading to thermoforming from metal has many advantages that provide the aesthetics required in today’s market at minimal cost.

There are several benefits for converting metal to a thermoformed part.  The four most important (benefits) are:

  1. Cost
  2. Weight
  3. Design Flexibility
  4. Material advantages

COST

  • The more complex the geometry of the part’s design the greater the cost savings. A customer may experience a cost savings of up to 50 percent on a conversion to plastic on a complex part.
  • As the part’s complexity and the production volumes increase the advantages of thermoforming grows exponentially. In a metal fabrication, investments in component ancillary tooling may be needed (stamping dies) to achieve shipment releases and cost reductions.

In-direct benefits include:

  • Decrease in weight will reduce assembly cost (one assembler rather than two).
  • Customer perception of an advanced product due to the flexibility of design and materials available to General Plastics.

WEIGHT

  • Thermoforming resins allow engineers to obtain the properties required, while allowing designers the flexibility to achieve the aesthetics required and reduces the cost and weight of the product.
  • Depending on the metal alloy, thermoformed plastics may be up to 75 percent lighter based upon specific gravity.

In-direct benefits include:

  • Fuel efficiency.
  • Decreased emissions.
  • Decreased noise and vibration levels.
  • Lower overall weight of the product.
  • Logistics/freight advantages.

DESIGN FLEXIABILITY

  • Ability to produce complex shapes and designs without secondary assembly steps. These same shapes manufactured in metal are expensive and may require ancillary stamping and tooling.
  • Ability to form logos and warning labels as well as other branding directly into the part.
  • Mating points easily designed in the part.
  • Multiple finishes on the same part.
  • Part Consolidation.

Indirect benefits include:

  • Decreased cost.
  • Decreased assembly time.
  • Decreased part numbers, carrying costs and inventory.
  • Increased aesthetics.
  • Part consistencies and repeatability from part-to-part as well as lot-to-lot.

MATERIAL ADVANTAGES

  • There are many thermoforming resins available – HIPS, ABS, PC, PE, TPO, acrylic and alloys – the correct material is matched to achieve the clients’ needed requirements and pricing.
  • Materials meet flame, smoke and toxicity requirements that are required by the transit industry.
  • Monolithic color eliminates painting.
  • Texture availability without cost implications on sheet.
  • Texture tooling for specific texture requirements.
  • No corrosion.

General Plastics, Inc. is your full-service thermoforming solution with more than 30 years of experience with expertise in the following applications:

  • Pressure forming (6’ x 10’)
  • Vacuum forming (6’ x 10’)
  • CNC & Robotic trimming
  • Full assembly and sourcing
  • Packaging and kitting
  • Prototype and production tooling
  • DFMA assistance
  • Design freedom for undercuts, texture and color

To discuss your Thermoforming needs, call General Plastics, 414-727-6855; Toll Free: (888) 611-0270 or email us sales@genplas.com.