Material selection is an important part of designing a successful vacuum formed plastic part, but the type of plastic isn’t the only consideration. Material thickness can also influence a part’s strength, weight, appearance, and performance. Understanding how thickness affects vacuum formed parts can help manufacturers make better decisions during product development.
What Is Material Thickness?
Material thickness, often referred to as gauge, describes how thick the plastic sheet is before it is formed. During the vacuum forming process, the heated sheet is drawn over a mold, causing the material to stretch and change thickness in different areas.
Because of this stretching, the starting thickness needs to be selected with the finished part in mind.
Thickness and Part Strength
In general, thicker material can provide greater rigidity and durability. This can be important for components that need to withstand regular handling, impact, or other physical demands.
However, choosing the thickest available material isn’t always the right solution. Part geometry, material type, mold design, and the intended application all contribute to the final performance of a vacuum formed component.
Weight and Material Efficiency
Material thickness also affects the overall weight of a finished part. For applications where reducing weight is important, using an appropriate gauge can help balance structural requirements with material efficiency.
Working with an experienced manufacturer can help determine the right combination of material and thickness for a particular application.
Appearance and Consistency
Thickness can also influence the appearance and consistency of formed parts. Complex shapes may cause material to stretch more in certain areas, making proper material selection and tooling important for achieving the desired result.
Designing with the forming process in mind from the beginning can help address potential variations before production begins.
Choosing the Right Thickness for Your Application
There is no universal material thickness that works for every vacuum formed part. The appropriate gauge depends on factors such as the part’s size, shape, intended use, material, and performance requirements.
The Pro Design Group offers vacuum forming using a range of material gauges to accommodate different applications. Explore our vacuum forming services to learn more about the process and available options.
Plan Your Part With Manufacturing in Mind
Material thickness is one of many factors that can influence the success of a vacuum formed component. Considering it early in the design and manufacturing process can help create parts that meet functional and production requirements.
For help evaluating your next project, contact The Pro Design Group.