The process of thermoforming is used to make unique plastic designs. Currently, the thermoformed plastic packaging is in huge demand.

The packaging team creates a thermoformed design by stretching a hot sheet of plastic over a mold to produce a unique design. Again, the packaging experts contain air pressure in a defined box to develop these packaging designs.

The packing team will then focus on trimming and assembling the design once it has cooled into the mold shape.

When the pressure on a plastic sheet surpasses 15 lbs. per square inch, up to 150 lbs. per square inch, thermoforming is utilized. Thermoforming is used in packaging for the food, electronics, and pharmaceutical sectors.

Types Of Thermoformed Plastic Packaging

Formation Of Vacuum

The first step of the thermoformed plastic packaging involves vacuum forming. Talking about vacuum forming, it is a “simple” variation of thermoforming in which a sheet of plastic stretches over or into a female mold.

This is used to create packaging designs that did not require depth or thickness. The plastic package design develops over the mold using negative air pressure. Vacuum forming is preferred by businesses since it is more cost-effective and has a more simplified procedure.

The vacuum forming machines are less expensive to operate, and the materials are also less costly.

Vacuum-formed packaging takes less time to create because the designs aren’t as detailed. Vacuum forming, on the other hand, does not produce as many products as other packaging design approaches, making it more suited for smaller runs.

Plug Assist Formation

To force the plastic material into the female cavity and create the plastic package design, a male plug tool is mounted over the machine.

Aluminum, urethane, or syntactic foam may be used to make the plug. As this method uses a uniform fill, each run can have a consistent thickness. Webbing in the packaging design can also be avoided with plug assist forming.

Formation Of Pressure With Plug Assist

Although plug assists pressure forming as well as plug assist forming are quite similar, there are several major differences between the two.

As in plug assist forming, a plug is mounted above the material, however, this time, air vented beneath the sheet applies pressure to the plug side. To achieve the required outcomes, the temperatures in plug assist pressure forming must remain constant.

Design Considerations For Thermoforming Or Thermoformed Plastic Packaging

Design Of High Quality

The creation of a great design is the first step in making good thermoformed plastic packaging. Almost everything else about your packaging, including materials, tooling, and more, will be determined by your design.

Explain to your packaging design team what you had in mind for your project. You should also tell them about any details regarding your product that they should be aware of when you sit down with them.

They will then recommend different structures that provide great levels of security while remaining attractive.

Thermoforming Or Thermoformed Plastic Packaging - Mermed

Material Choice

Following that, your group will choose the right plastic material. PET and PETG polymers are commonly used to make thermoformed parts by several firms. Both have advantages and can be used in several situations.

Tooling Of The Best Quality

Your team will need to construct specific tooling to create your box once you and your packaging company have decided on a design and materials.


So, these are some of the most important things that you should know about thermoformed plastic packaging and the way, in which it works.