Capabilities
Kal Plastics is your thermoforming department down the hall. Bring us your project, and we’ll present you with a solution. From concept to delivery, our staff will become an extension of your team.
Capabilities
Your project is our priority. We outshine others in the field by our 60+ years of experience, attention to detail, and unmatched customer service.
Thermoforming
Vacuum forming, also known as thermoforming, is the process of forming a heated sheet of thermoplastic over or into a mold. The sheet is then allowed to cool and form the desired part. Pressure forming gives parts an injection molded look without the cost.
Sample Applications
Kal Plastics has manufactured parts of all sizes and worked in every major U.S. industry.
Value Proposition
Backed by a dedicated and experienced team, we focus on innovation, efficiency, and quick turnaround times to meet our clients’ needs. Our production-oriented approach allows us to handle both large projects and smaller runs with the same level of care and precision.
Expertise
We have extensive experience working with specialty materials and prioritize the use of recycled materials whenever possible, helping our customers achieve high-quality results while supporting sustainable practices.
Industries Served
Agriculture
Consumer/Recreation
Spa, Educational, RV, Pet, Fitness
Automotive
Specialty Vehicles, After market
Construction/Housing
Food Service Equipment
Furniture
Office, Architectural
Material Handling
Industrial, Food
Medical
Trays, Durable Equipment, Housings
Point of Purchase Display (POP)
Telecommunications
Cellular
Traffic Safety
Transportation
Bus, Train, Air, Personal
Waste Management/Containment
FAQ
Why use vacuum forming?
Vacuum forming offers processing advantages over competitive processes such as fabrication, blow molding, injection blow molding, rotational molding, and injection molding. Because tooling costs are lower, relatively large parts can be economically fabricated. Vacuum forming is also ideal for prototyping and product development due to the lower tooling costs and faster turnaround. In many instances, a vacuum formed part is of higher quality and will last longer than an identical part made by a different process. This is especially true when comparing an injected molded part to the same part that was vacuum formed. Vacuum forming is also ideal for any part not expected to exceed a volume of 50,000 or more units.
What kinds of molds are used?
Vacuum forming tools used for prototyping can be made from a variety of materials. The material choice depends on the application and costs vary.
At Kal Plastics, we use REN board—a high-density, machinable tooling board ideal for prototyping, molds, and thermoforming fixtures. REN board offers fast machining and short lead times, lower up-front cost, and easy design modifications. It is also ideal for prototypes and short runs.
For production, tooling is typically machined or cast aluminum. These tools provide superior heat transfer and cycle efficiency, consistent part quality, and long service life with proper maintenance.
Are there any limitations with vacuum forming?
There are a few guidelines to vacuum forming that must be followed. Vacuum forming is more of an art than a science. No two jobs are alike, and every part presents its own unique set of challenges. There are many “tricks of the trade” to be considered when approaching a new job, so sometimes it may take some time to get a part right.
In terms of mold design, undercuts are not desirable and require special mold inserts which tend to greatly affect tooling costs. A draft is also needed in the mold so parts will pull off. Male molds require a draft ranging from 1½ degrees to 3 degrees, depending on the material. Female molds, on the other hand, usually require no draft if the mold is smooth and ½ degrees if textured. Ideally, parts should also have the same general cross section.
The most common limitation is part depth when utilizing a female mold. As a rule, the depth of a part cannot exceed 75% of the width or length, whichever is less.
What amount of lead time should I expect?
Lead times vary depending on the type of job. Custom or first-time jobs take the longest. When new tooling is required, four to six weeks is the average turnaround time for delivery of a first article. Production parts will be ready in approximately two to three weeks following first article approval. The standard lead time for custom orders not requiring new tooling is from one to six weeks, depending on which material is used. Stocking programs are available for custom items that allow us to deliver next day.
Experience shows us that tooling adjustments and working out individual forming challenges are the greatest obstacles when trying to shorten lead times. Each new mold or new job is a unique puzzle to solve and has its own special recipe for success.
Where can I learn more about thermoforming?
The Thermoforming Division is a chapter of the international professional association, Society of Plastics Engineers. The Division’s mission is to facilitate the advancement of thermoforming technologies through education, application, promotion and research. Learn more at https://thermoformingdivision.com.