Vacuum Thermoforming of a Costume Head for the Restaurant Industry

Hagans Plastics specializes in providing up-to-date solutions for a changing industry that includes molding, thermoforming and other precision services.

For the last 20 years, Hagans Plastics has been a head above its competition, literally. It’s not every day that you get to partner with a thirty-year-old American Icon, like Chuck E. Cheese.

In June of 2012, Chuck E. Cheese launched an updated, contemporized mascot. As such, all costumes used in the more than 570 store chain would need to be updated as well. Working closely with Cowan Costumes the latest figure was created. There were some technical challenges in the manufacturing of this part. The large depth to draw, a mold actuated retractable mouth piece, a color consistent material were all items we needed to consider from a thermoforming aspect. KYDEX® T material was chosen for its consistent draw ratios. There are also parts that we injection mold such as the eyebrows that we also do in house. From a hand mock up, Hagans Plastics utilized some of the latest technology available to develop a 3D model, such as a Faro laser scanner.

Individual parts were made for thermoforming, the front of the head, the back of the head, the ears, nose and the tongue and the master pattern tooling was made in house. The parts are trimmed and some secondary processes are performed before all of the parts are sent to Cowan Costumes for assembly. We at Hagans Plastics are proud to see the final result,…(smiling and happy children).

To learn more about how the most advanced thermoforming technology and machines can help you, please contact us.