Differences between Thick Thermoforming and Injection Moulding

Injection moulding involves melting plastic raw materials and then injecting the molten plastic into a mould under high pressure using an injection moulding machine, where it cools and solidifies into shape. Thick-sheet thermoforming, conversely, is a method of shaping plastic components through heating, vacuum suction, and cooling.

Regarding product suitability, injection moulding is ideal for high-volume production of items requiring high precision. While mould fabrication costs are relatively high, it enables the design of complex structures. In contrast, thick-sheet thermoforming is better suited for products with simple structures, single-sided moulding, and lower production volumes. It offers lower moulding costs and shorter lead times. However, it should be noted that thick-sheet thermoforming has limitations when handling complex structures, often requiring compensatory measures such as bonding with adaptor components.

Furthermore, blow moulding represents another prevalent plastic processing technique, particularly suited for producing hollow items such as bottles and containers. This process involves placing a tubular plastic parison—formed via extrusion or injection moulding—into a mould cavity, where compressed air is introduced to expand and conform the material to the mould’s inner surface. Blow moulding tooling costs are comparable to vacuum forming moulds but remain relatively lower than injection moulding dies.

In summary, thick-sheet thermoforming, injection moulding, and blow moulding exhibit significant differences in product applicability, moulding costs, and process principles. The selection of a particular process depends on the specific requirements of the product and considerations of production costs.