Heavy Gauge Thermoforming

Rounding out the capabilities of VisiPak is heavy gauge thermforming, also known as large gauge thermoforming or thick gauge thermoforming.
It is these latter two names that helps understand what products and industries are best served by heavy gauge thermoforming.

What is Heavy Gauge Thermoforming?

First, let’s review the opposite to help explain differences between thin and heavy gauge thermoforming.

Thin Gauge Thermoforming

To contrast, let’s recall that thin gauge thermoforming uses rolled sheets that are placed over a mold until cooled. Thin gauge material is dominant in the disposable packaging sector, especially in the retail markets, particularly because of the light-weight aspect. Another primary reason for its popularity is the recyclability of the end product. Also, less material is often considered of value with thin gauge products.

Thick or Heavy Gauge Thermoforming

Heavy gauge thermoforming, on the other hand, uses pre-cut stacked sheets. Heavy or thick gauge material is often needed for very large and sturdy items with much lower volume requirements than thin gauge thermoforming. These large gauge thermoformed parts are designed to exist for very long periods of time, not as disposable items.

VisiPak is capable of manufacturing with the maximum sheet size of 36″ x 60″. The thickest material we run is 5/16″.

Heavy Gauge Thermoforming Applications

Heavy or thick gauge thermoforming is commonly used to produce permanent components in such things as refrigerators, automobiles, spas, car bumpers, heavy duty medical equipment, fitness equipment, construction equipment, and even plastic lawn chairs. Each of these assume a similar characteristic – they are larger items. Heavy gauge thermoformed products tend to be more sturdy. Large objects require large sheets and are often produced one at a time. These traits make large or thick guage thermoforming best suited for items requiring durability and lower volumes. For example, here is an image of a large gauge thermoformed tray, designed with sections and ribbed interior walls.This example is typical of a parts handling tray, which are stackable and reuseable.

Manufacturing Differences

A key difference between thick and thin gauge thermoforming is that in thin gauge thermoforming, a production run can create multiple pieces simultaneously, as seen with the clamshells shown here. In this example, the mold was designed to produce five pieces across and possibly four rows, allowing for 20 clamshells to be formed in a single pass. Thick gauge thermoforming parts are produced one at a time.

The creation of a heavy gauge thermoformed product involves specific machinery, processes and control systems. Each has its own uniqueness, but collectively the systems enables operators to develop their expertise not only in operating the machines, but in identifying advantages for efficiencies. Specifics about materials, timing, and heat exposures can prove to be critical.

Heavy Gauge Thermoforming Services

All heavy gauge thermoforming is custom designed, which is an expertise of VisiPak. From conception to final assembly, VisiPak engineering expertise will contribute to your bottom line by giving full consideration to design from start to finish. VisiPak Engineers assist in the entire product development cycle, applying your shared knowledge and requirements to create a design that meets with your approval, create prototypes for testing, oversee tooling production and review production outcome. VisiPak is one of the few manufacturers who can provide both thin and heavy gauge thermoforming services.

Using over 200,000 square feet, VisiPak provides heavy gauge thermoforming from three facilities:

Arnold (St. Louis), MO, Building 1

Arnold (St. Louis) MO, Building 2

Portland, OR Facility

Heavy Gauge Thermoformed Materials

Thin gauge thermoformed products are produced from thermoformed plastics, or thermoplastics, which makes them ideal for recyclability. They do not form chemical bonds during the curing process so at low melting points they can be reheated and reshaped.

This is not the case with the heavy gauge thermoformed products. The plastic used to produce items of thick gauge are considered thermoset plastics. The curing process involves chemical reactions that are irreversible. They can withstand high temperatures without losing their shape. They are “set” permanently. Additionally, smooth or textured finishes can be achieved at the sheet extrusion phase or within the final molding phase. PVC is the most commonly used material.