Industries Served
Plastics have differing characteristics and come in various types, sizes, materials, and colors. Due to its versatility, durability, and lightweight nature, manufacturers in retail, automotive, construction, and other major sectors increasingly rely on plastic as a vital material for producing quality prototypes and end-use parts. These can range from paint liners and clamshell packaging to interior paneling and trim pieces for vehicles.
Thermoforming services provide a flexible, cost-effective solution for shaping plastic sheets, driving market growth within many industries. The process involves heating a plastic sheet and placing it over a mold, using a vacuum or positive pressure to form it into the desired shape. The ideal thermoplastic material can vary depending on the project and the desired characteristics of the final product.
Thermoforming has numerous advantages over other molding methods, including:
- Low tooling costs
- Fast product development
- Quick and efficient prototyping
- Unlimited design options
Lerner Molded Plastics uses thermoforming to address the manufacturing needs of a broad range of applications in the automotive, construction, and retail industries. The versatility of this manufacturing process allows our customers to enjoy cost benefits and improved efficiencies of thermoformed plastics.
Automotive Industry
Thermoforming offers the flexibility to manufacture aesthetically pleasing and customized packaging solutions for automotive applications. For instance, thermoformed packaging clamshells and blisters fit snugly around a product and are extremely secure and durable. ESD-protected packaging protects critical car components from electrostatic discharge, providing an added layer of protection.
Automotive applications also depend on various tools, materials, and components to repair, build, and maintain vehicles. At Lerner Molded Plastics, we utilize thermoforming to manufacture the following automotive parts:
- Bumper fascia
- Interior door panels
- Dashboards
- Trim pieces
- Spoilers
Our custom thermoforming capabilities allow us to accommodate larger part sizes and various weight requirements for customers in the automotive industry.
Benefits of Thermoforming for Automotive Applications
Utilizing the thermoforming manufacturing process to produce automotive parts offers two key benefits:
- Time. To ensure the utmost efficiency, we prepare the plastic sheets for thermoforming while designing and developing an aluminum 3D mold. The entire process usually takes approximately 14 weeks from the start of the initial concept to shipping for delivery.
- Cost. Automotive thermoforming is a reliable and inexpensive technique for molding plastic components. Our process suits small and larger production runs due to its relatively low tooling costs.
At Lerner Molded Plastics, we can use thermoforming to achieve high-quality surface finishes that paint well and function as desired in the intended application. We can also accommodate specific texture and surface treatment needs.
Construction Industry
Thermoforming construction materials have distinct advantages over traditional production methods. Not only does it create more durable parts, but it can also handle larger components during the manufacturing process. These parts generally require little to no maintenance and are easy to install.
Thermoforming is suitable for manufacturing construction parts such as:
- Insulation vents
- Paint liners and trays
- Shower enclosures
- Window well covers
At Lerner Molded Plastics, we use materials that meet industry standards and are durable enough for heavy-duty applications. We can also customize cut sheet sizes according to our customers’ specific requirements.
Common Materials and Molding Methods for the Construction Industry
Cut plastic sheets typically consist of the following materials:
- Acrylic
- Acrylonitrile butadiene styrene (ABS)
- Polypropylene (PP)
- Polystyrene (PS)
- High-density polyethylene (HDPE)
- Polycarbonate (PE)
- Polyester (PET / PETG)
Lerner Molded Plastics has the necessary thermoforming equipment and resources to meet the demands of various construction applications. We can produce top-quality building materials on single-station, rotary cutting, or in-line thermoforming equipment while utilizing pressure forming or twin sheet vacuum forming methods on the given material.
Retail Industry
Thermoforming is an innovative and effective solution for everything from electronic components and household goods to toys and intricate consumer goods. The method is a mainstay of clients in the retail industry due to its protective qualities, cost-effectiveness, and convenience. It also offers unique visual advantages for branding purposes, catering to a range of retail packaging needs.
Common Applications of Thermoforming in the Retail Industry
The following retail applications can benefit from thermoforming:
- Plastic clamshells. The versatile packaging solution is lightweight and commonly used to hang, stand, or attach to product displays. It is also pilferage-proof and ideal for selling and protecting consumer product goods in retail settings.
- Plastic insert trays. Designed to showcase consumer product goods, these insert trays provide exemplary protection in retail environments. Thermoforming can create the ideal fit and additional stability for this packaging solution.
- Trapped blister packaging. A thermoformed plastic blister package is placed between two paperboard sheets and sealed via pressure or heat to form a secure packaging solution. It is pilferage-proof, making it a common packaging choice for retail settings.
- Plastic blisters. Plastic blister packaging is an easy and affordable method to protect and display small, lightweight consumer products.
Thermoformed retail packaging from Lerner Molded Plastics yields bottom-line results in terms of cost, performance, and merchandising value. We can help you protect products while fully showcasing them in the intended setting.
Lerner Molded Plastics: Thermoforming Services for Diverse Industries
Lerner Molded Plastics is a group of plastic manufacturing experts committed to providing exceptional quality with every project. Our extended team encompasses long-established companies that are financially sound, with a proven track record of customer satisfaction and unsurpassed experience in a variety of plastics processes, including thermoforming for the automotive, construction, and retail industries.
Our in-house and contract plastics manufacturing capabilities include:
