Metal parts have traditionally been a go-to solution for heavy-duty needs. However, there are some major challenges that arise when relying on metal components. Increased costs, heavier weight, corrosion risks, and longer lead times can all eat into profits or cause issues for the end-consumer. That’s why thermoformed plastics have become a popular alternative to metal components. With the right custom thermoforming team, you can avoid these common issues and improve your overall results. Below, we’re exploring the benefits you could expect from switching to thermoformed plastic components.
Common Challenges With Metal Parts
High Material and Processing Costs
One of the most pressing concerns with metal manufacturing is the high expense. Rising material costs continue to squeeze budgets, while expensive tooling and machining requirements add substantial overhead to production runs.
Excessive Weight
Weight is another consideration to keep in mind. Heavier parts can drive up shipping costs, which eat into your company’s budget. Excessive weight may also place added strain on assemblies, compromising product performance.
Corrosion and Environmental Degradation Risks
You’ll also have to consider corrosion and environmental degradation risks. These issues may mean constant maintenance concerns and the potential need for premature replacement.
Long Lead Times and Limited Design Flexibility
Metal parts also often have long lead times. The manufacturing process can become a bottleneck due to slow prototyping and revision cycles. This could mean delayed product development and difficulty accommodating design changes mid-project.
How Custom Thermoforming Solves These Challenges
Because of the issues with metal parts, many businesses are switching to custom thermoforming for plastic components. This process involves heating up a plastic sheet until pliable, then laying it over a mold. It takes the shape of the mold, which shapes it into products like packaging, automotive parts, trays, and more.
Lightweight and Durable Components
Unlike metal components, thermoformed products are lightweight. They can deliver significant weight reduction compared to metal parts, while maintaining durability. With less weight, you’ll experience reduced shipping costs and less strain on assemblies.
Corrosion Resistance and Longevity
Thermoformed products don’t face the same corrosion risks that metal components do. Many plastics can withstand exposure to moisture, chemicals, and UV radiation without degrading. This makes them ideal for harsh environments where metal would quickly deteriorate.
Greater Design Freedom
Customers particularly appreciate the greater design freedom that thermoforming provides. You can more easily accommodate complex geometries and other design aspects that may be difficult to achieve with metal fabrication. This allows teams to refine products quickly and easily respond to changes.
Shorter Lead Times
One of the most valuable aspects of thermoforming is its shorter lead times. It offers faster prototyping and production cycles that often allow you to get to market faster.
Trust Allied Plastics for Your Thermoforming Needs
For the last 30 years, Allied Plastics has been a leading provider of plastic sheet extrusion services. When you partner with us, you know you’re getting quality products at a competitive price.
Our Twin Lakes, Wisconsin, facility boasts some of the largest plastic thermoforming machines in the country. These machines have twin sheet forming, single sheet forming, drape forming, pressure forming, and sheet over forming capabilities. With lean manufacturing principles and short lead times, we’re ready to take on your next project.
From concept to production, we’re your trusted partner. Our world-class engineering team is well-versed in creating custom components that meet your exact needs. And, our quality professionals are trained in the production part approval process, initial sample inspection reports, and part submission warrants. Additionally, we maintain ISO 9001:2015 and ISO 14001:2015 certifications to ensure quality.
Let’s Get Started
Our team is ready to create custom thermoformed products for your business. Contact us today to learn how we can help you.