Optimal Technology for Every Task

Thermoformed parts produced by single-sheet technology for various applications and industries make almost limitless individuality of design, material and form size possible.

The DUROtherm Group has more than 28 thermoforming units altogether for the production of single-sheet thermoformed parts in various sizes from major suppliers. Apart from vast production capacities, this big machinery has the advantage that each order can be produced on a machine suited for the respective thermoformed part. But even as regards the sizes of forms DUROtherm is a decisive step ahead of the competition: Huge parts up to a size of 4200 x 2500 mm can be produced in one of the biggest thermoforming plants for contract manufacturing in Europe.

The Single-Sheet Process

In the single-sheet process a firmly clamped plastic sheet is first heated on both sides. While the mould is moving upwards compressed air is used to pre-stretch the hot sheet. The air between the mould and the sheet of plastic is then evacuated and atmospheric pressure causes the sheet to conform to the mould.

Afterwards a cooling fan cools the thermoformed component below the solidification point of the plastic. A flow of compressed air releases the finished thermoformed part from the mould.

Thermoformed parts which are manufactured by twin-sheet process are characterized by extremely high stability, which makes this technology ideally suitable for the production of load carriers. Contrary to single-sheet thermoforming not only one sheet but two sheets of plastic are being thermoformed simultaneously. Which is why thermoformed parts can have different shapes and colours on each side and be enormously rigid.

DUROtherm produces twin-sheet thermoformed parts on five units. For this reason, DUROtherm is one of the leaders of this industry as for this production technology. Among these units are two rotary carousel machines, which win over by high press force as well as high cycle times. These units are among the biggest of Europe with sizes ranging up to 3200 x 1800 mm or 3300 x 1300.

The Twin-Sheet Process

In the twin sheet process two firmly clamped plastic sheets are heated on both sides in separate ovens. The panels are then moulded one after another by evacuating the air between the mould and the

hot plastic sheet. Subsequently, the warm thermoformed parts are welded firmly together using pressure. A flow of compressed air is then used to release the finished twin-sheet part from the mould.

With the PU-foam technology we can do both, produce homogeneous foam parts as well as combine thermoformed parts with foam: So it is possible to backfoam single-sheet thermoformed parts or fill twin-sheet parts with foam and to deliver them complemented by this production step Thermoformed parts which are refined with PU-foam feature good thermic or acoustical insulation. Additionally, the stability of the thermoformed parts can be increased drastically at relatively small increases in weight. Attachment points, fixing aids or the inclusion of functional elements can be integrated in the production process.

We can produce formed parts by RRIM-technology on hybrid machines, which are extremely impact-absorbing and thermostable.