Components which are relatively simple and shallow in form are thermoformable from Foamalux and Foamalux Ultra heated to an elastic state.
Air-pressure forming is possible at about 130°C and pressures of about 2 bar and vacuum forming at about 170°C. As the material has relatively low density, heating and cooling cycles are faster than with solid thermoplastics. Higher temperatures enhance definition but at the expense of surface finish.

Most industrial press and vacuum formers for thermoplastics are suitable. Best results are achievable from machines which controllably heat both sides of the sheet. Large area panels and thick panels need some air pressure support during heating to avoid sag. Prior conditioning, by suspending in an air circulating oven at about 130°C, removes inherent stresses.
Male moulds are suitable for vacuum forming, female moulds for vacuum and pressure forming. Secure clamping of the sheet during forming is essential to avoid shrinking: components must be completely rigid before removing from the mould.
When an item involves screen printing and thermoforming for its production, the thermoforming processess should always precede the printing.

Pressure Forming In A Female Tool

Vacuum Forming In A Female Tool

Vacuum Forming In A Male Tool