Thermoforming – a versatile and cost-effective process for creating high-quality plastic parts – is a core competency at Bankier Companies.  For over 35 years we’ve been fine-tuning our thermoforming capabilities, improving the process, materials, and equipment we use to offer every new advancement in technology for our customers and their projects.

The Thermoforming Advantage

At its heart, thermoforming involves heating a plastic sheet until pliable, then forming it over a mold to create a precise shape. This single-sheet approach allows for efficient production of multiple parts per draw, reducing per-unit costs.

Vacuum forming, a common thermoforming technique, utilizes a vacuum to pull the heated plastic sheet even tighter onto the mold, ensuring intricate details are captured. After cooling, the excess plastic is trimmed away, resulting in the final part.

Benefits of Thermoforming

• Cost-effective: Thermoforming offers a cost-competitive alternative to injection molding, especially for low- to medium-volume production runs.
• Fast turnaround times: Compared to injection molding, thermoforming typically requires less upfront investment in tooling, leading to faster production timelines.
• Material versatility: A wide range of thermoforming materials exist, allowing for the creation of parts with specific properties like rigidity, transparency, food safety, heat resistance, and UV resistance.
• Design flexibility: Thermoforming can accommodate a wide range of shapes and sizes, including complex geometries that might be difficult or expensive to achieve with other methods.
• Short-run suitability: Thermoforming excels in creating smaller production batches, making it ideal for prototyping or situations where initial demand is uncertain.

Material Options

Bankier Companies offers a comprehensive selection of thermoforming materials to suit various project requirements. Some of our most commonly used materials include:

• HIPS (High-impact polystyrene): A cost-effective option known for its good formability and rigidity.
• PETG (Polyethylene Terephthalate Glycol): A high-impact and durable material offering excellent clarity and chemical resistance.
• ABS (Acrylonitrile Butadiene Styrene): A versatile plastic known for its strength, rigidity, and good paintability.

We provide detailed data sheets for each material, allowing you to make informed decisions based on your specific needs.

Tooling Solutions

Thermoforming requires molds and trim jigs. Traditionally, these tools were machined from aluminum or urethane. However, 3D printing technology has revolutionized thermoforming tooling, particularly for smaller parts.
3D printed molds offer significant advantages:

• Reduced lead times: 3D printing allows for faster mold production compared to traditional machining methods.
• Lower costs: 3D-printed molds are often more cost-effective than machined alternatives, especially for prototyping or low-volume production runs.
• Complex geometries: 3D printing can readily produce intricate shapes, including undercuts, that might be impractical or expensive with machining.

Your One-Stop Shop for State-of-the-Art Thermoforming

Bankier Companies provides a comprehensive suite of thermoforming services, encompassing every stage of the process:

• Design assistance: Our team can collaborate with you to optimize your design for successful thermoforming.
• Tooling fabrication: We leverage both traditional and 3D printing techniques to create molds and jigs that meet your project requirements.
• Thermoforming production: Our skilled technicians utilize state-of-the-art equipment to produce high-quality thermoformed parts.
• Post-production services: We offer a full range of finishing options, including machining, product assembly, and contract packaging, to deliver complete solutions.

Partner with Bankier Companies for your next thermoforming project.  Our expertise, material selection, and commitment to quality ensure exceptional results that meet your budget and timeline. Although we are known as a leading American thermoforming company, Bankier Companies does so much more. Whether you need injection molding, supply chain management, or warehousing and distribution, we have you covered. Contact us today to discuss your specific project needs.