Hagans Plastics Co., Inc. offers additional services to include up-stream assembly of parts by our trained staff. Quality and service are Hagans Plastics priorities.
Twin Sheet Forming is often used as a higher quality alternative to rotational and blow molding. This process is used when hollow products are produced at high rates of speed. Twin sheet forming usually uses female molds. Both vacuum and pressure are used to form the part. The steps involved in this process are first two heated spaced sheets are fed between halves of an open mold, a blow pin will enter between the sheets, a very fast vacuum is introduced to each half of the tool and the mold will be closed. Both vacuum and pressure are introduced to allow the material to form the part. The mold then will open to allow the release of the part.
Twin Sheet Forming has many unique advantages over other types of forming. All thermoplastics that are available in extruded sheet form can be Twin Sheet formed. Materials used can be of different colors to offer a unique looking part. The material does not have to be of the same thickness and for strength, the part can be foam filled after forming. The cost of the tooling is lower than that of blow molding and can offer design features that will produce both a rigid part and one that is lightweight. Twin Sheet parts can also be produced at a faster rate, lower cost and higher volumes than that of rotational molding. You will also achieve a more uniform wall thickness and consistent part over rotational molding.
At Hagans Plastics, the process does not stop at forming a part. With our advanced technology, we can also offer additional related services such as deburring, drilling and light assembly. Our forming quality has put the parts made into industries such as aerospace, automotive, electronics, medical, food, consumer products, and even on the space station.
Case Studies See all
Vacuum Thermoforming of Custom Seat Backs for the Aerospace Industry
The project highlighted here is for the fabrication of a custom seat back cover that was and is being used by Virgin America. Starting in 2004, one of the most challenging aspects of this particular seat back is the creation of the ultra-high gloss and brilliant white appearance.
Vacuum Thermoforming of a Costume Head for the Restaurant Industry
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.
Thermoforming of a Closeout for use in the Military Industry
The project highlighted here was a closeout part for unmanned drones used in the military. The part carried a high level of difficulty in the forming and the trimming operation and featured a severe undercut/trap on the mold.
Thermoforming of an Electronic Enclosure for the Electrical Industry
The project highlighted here was an electronic enclosure with EMI shielding designed for use in electrical testing. The customer supplied a 2D CAD drawing, and the part went through four complete design changes with small production runs done on each of the designs.
Thermoforming of Antenna Cover for use in the Telecommunications Industry
The project highlighted here is a radome, sometimes called a nose cover, for an antenna system used in the telecommunications industry. The customer supplied a 3D model of the antenna system along with a 2D CAD drawing.
Vacuum Thermoforming of an Advanced Medical Training Simulator
ACDET’s AbSim is an advanced medical training simulator that teaches student doctors and nurses how to perform a physical abdominal palpation exam.