Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation
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More About This Title Advanced Thermoforming: Methods, Machines and Materials, Applications and Automation


Introduces the latest innovations in thermoforming materials, processes, and applications

Advanced Thermoforming brings readers fully up to date with the latest standards, processes, materials, and applications in the field. From forming to filling to sealing processes, the author explains everything that can now be accomplished using the most advanced thermoforming technologies available. Moreover, readers learn how to fully leverage these technologies in order to design and manufacture products that meet all specifications at minimum cost and maximum efficiency.

Emphasizing the application of advanced thermoforming for the production of technical parts and packaging, the book:

  • Guides readers through all facets of development, design, and machine and mold technology

  • Recommends new technologies that offer higher productivity, better quality, and lower costs

  • Describes common raw materials used in thermoforming, including how specific materials affect the production process

  • Explains the proper handling of semi-finished products and formed parts

  • Sets forth the basic principles of extrusion, an essential process underlying thermoforming

  • Introduces the latest software techniques to simulate the thermoforming of new products

Throughout the book, readers learn about the latest innovations in thermoforming, from thermoformed automobile body parts to fully automated packaging assembly lines. The author offers valuable content from his interviews with leading industrial thermoformers, sharing insights and tips from their years of hands-on experience with readers.

With Advanced Thermoforming as their guide, polymer and plastics engineering professionals and students can now explore and exploit the full range of possibilities that thermoforming technology offers.


Sven Engelmann is the Director of Polymer Technology at Gerhard Schubert GmbH, where he leads the development of thermoforming technology. He is also a lecturer on thermoforming at the University of Stuttgart and the Aalen University of Applied Sciences in Germany.


Preface xi

1. Introduction 1

2. Basics of Thermoforming and Thermoplastics 5

3. Production of Semifinished Products, Extrusion, and Coextrusion 12

4. Introduction to Technical Parts 28

5. Antenna Radome Manufacturing 29

6. Fuel Tank Production on Sheet Machines 33

7. Automotive Body and Commercial Vehicle Applications 41

8. Production of Refrigerator Liners 48

9. Paint Replacement in Automotive Applications 61

10. Motor Air Intake Made from PA 6 GF 15 70

11. Sanitary Equipment (Sheet Machine) 72

12. Thermoforming and Milling of Large-Scale Formed Parts (Sheet Machine) 76

13. Changeover of Sheet Machines 84

14. Chromed Parts 92

15. Applications in Aircraft and Mass Transportation 94

16. High-Quality and Fully Transparent Products (Sheet Machines) 103

17. Deco Molding and Multi-deco Molding 106

18. Automotive Body Parts Made of PA + ABS 119

19. Softfeel Made from ABS/TPU Material 121

20. Introduction to Packaging 124

21. Optimizing a Thermoforming Process for Packaging 125

22. Analysis of Thermoforming Films 137

23. Advanced Analysis of Thermoforming Films 144

24. Analysis of Thermoformed Products 151

25. Analysis of Completely Formed, Filled, and Sealed Containers 160

26. Automated Packaging 167

27. Production of Flowerpots 179

28. Steel Rule Die Punching 197

29. Production of Meat Trays 200

30. Multilayer Films for Thermoforming Applications 208

31. PET in Thermoforming Applications 211

32. Thermoformed Packaging Made of PLA 227

33. Peel and Reseal 232

34. Foam Packaging with PP and PS 250

35. Blister Packaging of Syringes 257

36. The Production of Drinking Cups 264

37. Ultrasonic Sealing and Cutting in Thermoforming 287

38. Understanding the Brittle Behavior of Polystyrene Cups 293

39. Preprinted Film for Lid Thermoforming 308

40. Flexible Films 311

41. Simulation 316

42. Recycling 324

Glossary 328

Index 329


“Overall, this text presents an impressive variety of advanced thermoforming technologies in a very readable form.”  (Materials Views, 21 August 2013)