CW ThomasThermoforming

CW Thomas

• Custom manufacturer of heavy gauge thermoformed plastic parts. (START THICKNESS 0.047 TO +0.500)

• No proprietary products – all custom work.

• We utilize advanced vacuum and pressure forming techniques.

• We couple that with state of the art CNC trimming and assembly services to produce your item.

2

General information

CW Thomas

• Privately held company.

• Established 1946.

• 1 Manufacturing location 80,000 square feet.

• 55 Employee’s with an average Tenure of 20+ years of service.

• ISO-9001: 2008

• AS: 9100C

• 2 Full Time Shifts

• Non- Union

A little more About Us

3

CW Thomas

• Aerospace – Aircraft Seating – Interior

Parts

• Rail Transportation – Rail Car Interior

Parts

• Medical Diagnostic Equipment

• Laboratory Equipment

• OEM’s

What we do – Industries We Serve

4

5

Services• Engineering Services

• Review part design for product enhancements and manufacturing efficiencies

• In-House Tooling → quick turnaround times / quality

• Rapid prototyping

• Prototype and Production Parts• Vacuum and pressure forming techniques

• Prototype parts in approximately 4 to 6 weeks

• State of the art CNC trimming

• Post-Forming • Assembly (including hardware/electronics, gluing and applying fasteners and strips into a component, ultrasonic welding)

• Painting and printing

• Dock-to-stock: packaging solutions where parts are inspected and shipped in the customer's packaging and pallets

6

CW ThomasWhat is Thermoforming?

• Thermoforming is a broad based term that means to Stretch a Flat sheet of Plastic using Heat, vacuum and air pressure into a 3 dimensional Shape using a mold.

• It can basically be divided into 3 categories:

• Vacuum Forming, Pressure Forming and Twin Sheet.

7

Vacuum Forming - Machine

8

Tooling – The Heart of your Part

Of the many things required for a successful Thermoformed Part perhaps the most important is the Design of the

Tooling.

Properly design molds and trim fixtures made from the correct choice of materials will transfer into

consistent quality finished part for the life of your program.

9

Assemblies

• Bonded Mounting Blocks and Bosses

• Threaded Inserts

• Painting, Shielding, Screen or Pad Printing, Graphic Overlays

• Complete Assemblies in Your Packaging for Direct Shipment

10

Thermoforming vs. Injection Molding

Both processes are viable to manufacture 3D polymer parts. How do we help the customer decide which

process is best for their next project?

11

Process Overview

12

Thermoforming Injection Molding

Tooling A single sided 3D form is created out of aluminum

A double-sided 3D mold is created out of steel, aluminum or a beryllium-copper alloy

MaterialsFlat sheets of thermoplastic, available in a variety of materials, finishes, colors, and

thickness

Thermoplastic pellets, available in a wide variety of materials and colors

Production

A flat sheet of plastic is heated then molded to the tool’s shape using either suction from a vacuum, or both suction

and pressure

The plastic pellets are heated to a liquid state and then injected into the mold

FinishingThe final pieces are trimmed robotically, then can be used uncoated, painted or

have specialty coatings

The final pieces are removed from the mold, then often need to be painted and be silk-

screened or have specialty coatings

Other Considerations

Thermoforming Injection Molding

Tooling Costs $$ $$$$$

Per-Piece Production Costs $$$ $

13

Creating a single sided thermoforming tool is much cheaper than creating a double sided mold to be used in injection molding. However, the cost of each individual part is generally cheaper

with injection molding.

Cost Comparison – Sample 48” x 60” Part

14

Leadtime

Thermoforming

• 8 WeeksInjection Molding

• 16 Weeks

15

Other Considerations

Thermoforming Injection Molding

How does it look unpainted? Excellent Highly Variable

Does it allow variable thickness within a single part?

Limited Yes

How large a part can it reasonably produce?

5’ x 9’ 4’ x 4’ (on standard equipment)

16

Guidelines to choose the appropriate process

Thermoforming1. Part Size

• Creating large parts up to 5’ x 9’, and consolidation multiple parts into a single large part

2. Run Size

• Creating small to medium (100 – 3,000) runs of parts

3. Aesthetics

• Aesthetically pleasing unpainted part

Injection Molding1. Part Size

• Creating small parts with minimal consolidation

2. Run Size• Creating large runs (3,000+) of small to medium-sized

parts

3. Variation• Creating parts with variable thickness in a single part

17

CW Thomas Process & Capabilities

• Pressure Forming• Pressure forming provides parts that are visually identical to injection molded parts at

a fraction of the tooling cost.

• Vacuum Forming• Vacuum forming produces a one-sided part whereby the sheet color and texture

provide finished part aesthetics.

• Large Part Vacuum Forming• Reduce the number of overall components by combining multiple parts within a 5’ x 9’

sheet size.

CW Thomas versus other Formers

• Strong Engineering and Quality Departments• If a customer visits our facility, we usually win the business

• Ability to process high performance polymers• Expertise in challenging high performance polymers such as ABS and other

Polycarbonate, Kydex / Boltaron (Acrylic/PVC) and Ultem (PEI).

• Capabilities to process Polyethylene/Polypropylene, PVC, Engineering resins

• Value-Added Services• In-house tooling → quick turn-around times / quality / rapid prototyping

• Post forming services: assembly, painting and printing, and dock-to-stock.

19