A Brief Introduction
Extrusion plastic sheet is a process of heating and melting plastic particles and extruding them into sheets.
Firstly, we need to buy plastic particles from CHIMEI and Sinopec Corporation, which are famous plastic suppliers. We can have many different plastic particles, such as
- ABS
- ASA
- HIPS
- PS
- Acrylic(PMMA)
- HDPE
- PETG
- PC
- PP
With our extrusion production lines, we can meet different clients’ requests. The color and other performance, like UV protection, fire-resistance, high-impact, corrosion resistance, and you can choose the different textures for the surface of plastic(we have some textures for you to choose from). Moreover, the plastic sheets also can be one-layer, two-layer, and even three. Using this way, we can combine the advantages of different materials to make the most suitable material for customers. For instance, ABS and ASA are two kinds of material that are quite similar, but ASA has a special characteristic of strong UV protection, which is very suitable for outside use. But ASA is more expensive than ABS, so we can do the plastic sheet with ABS at the bottom and ASA attached on the top of ABS, then we can get a good price and a good performance. The same reason applies to ABS+Acrylic, this kind of material is usually for baths or high glossy surface projects. As we know, pure Acrylic is quite crisp, so we can combine it with ABS materials which can add flexible performance. Ditai has two sets of extrusion production lines, not only the price but also can control the quality from the source and shorten the production time to a great extent! Contact Us: [email protected]
Understanding Material Shrinkage Rates in Vacuum Forming Mold Design
At DitaiPlastic, every project begins with a critical decision: choosing the right material. This choice is not just about aesthetics or function; it also significantly impacts the mold design process, particularly in vacuum forming, where material shrinkage rates must be carefully considered.
Material shrinkage rate refers to the reduction in the material’s dimensions as it cools after forming, which directly affects the accuracy of the final product. For example, Polyethylene (PE) and Acrylonitrile Butadiene Styrene (ABS) have different shrinkage rates, meaning they cannot use the same mold. PE, with a higher shrinkage rate typically between 1.6% to 3%, requires molds to be designed larger to account for this reduction. ABS, on the other hand, has a lower shrinkage rate, around 0.4% to 0.7%, necessitating different mold dimensions.
Conversely, ABS and Polystyrene (PS) have similar shrinkage rates, generally between 0.4% and 0.8%, allowing molds designed for ABS to often be used for PS, providing flexibility in production.
At DitaiPlastic, we meticulously tailor mold designs to match the specific material’s shrinkage characteristics, ensuring accurate and high-quality products. Understanding and accommodating these rates from the very start is essential to achieving precision in vacuum forming, ensuring your project’s success from material selection to the final product.
Video Showcase
Material Recommendation
| plastic material | advantage | disadvantage | industry example |
| ABS (Acrylonitrile Butadiene Styrene) | Engineered plastic that can be customized to desired levels of stiffness, hardness, heat deflection, and many other characteristics | UV sensitive – requires a UV protective cap layer for extended exposure | UV sensitive – requires a UV protective cap layer for extended exposure |
| PS(Polystyrene) | Clear plastic, very moldable, inexpensive, recyclable, high chemical resistance, high electrical resistance, heat distortion -200T | Cracks and breaks easily | Disposable cups, disposable applications, decorative applications, electrical applications |
| HIPS (High Impact Polystyrene) | Very moldable, relatively inexpensive | Very moldable, relatively inexpensive | Picture frames, shower walls, food containers |
| PVC (PolyvinylChlorid e) | Very high chemical resistance, stain resistant, stiffer than ABS, high room temp, impact strength, natural flame retardant qualities | Difficult to process | shower surrounds, moldings, kick panels, display cases |
| Polycarbonate | Extremely high impact resistance, high clarity – good for transparent parts, precision molding, good insulator, high heat distortion point ~270°F | Low chemical resistance to certain substances (oil, gasoline, harsh chemicals), can be difficult to process, higher material and processing cost | Visors, plastic guards, transportation components (headlights, taillights, instrument panels), appliance drawers, skylights |
| Polycarbonate/A BS | When compared to true polycarbonate -less expensive, lower heat distortion ~240°E much easier to process, higher chemical resistance | When compared to true polycarbonate – reduced clarity, lower heat distortion ~240°F | When compared to true polycarbonate 一 reduced clarity, lower heat distortion 〜240°F |
| PETG (polyethyleneterephthalate) | Very easy to process, high clarity -good for transparent parts | NotUV stable – unsuitable for extended exposure | Structural automotive parts, hand tools, industrial components |
Specific analysis of specific issues - customer suggestions section
Customized Textures for Solid Color Sheets:
For solid color sheets, customized textures are also feasible. When the sheet is not completely cooled and extruded, different surface effects can be added to the sheet by relying on different texture rollers. Compared with making textures in the mold, the texture is directly pressed out on the sheet. Although it will bring a certain degree of stretching during the vacuum forming process, the texture effect is more obvious, and there are certain restrictions on the texture effect on the mold. First of all, the mold is required to be solid aluminum, which is more expensive and can only be done using the reverse suction process. DitaiPlastic not only provides single-sided textures but also can make the sheet have textures on both sides. Common textures include frosted textures, electronic textures, diamond textures, Lychee textures, etc., and peach blossom textures, hair-cell textures, imitation cloth, etc. can also be provided. For leather effect materials, we can also make a layer of leather material when it is not completely cooled to meet the needs of various material effects. Generally speaking, the sheet with textures is scratch-resistant. For the smooth surface, that is, the sheet without textures, also known as glossy surface sheet, we will attach a layer of film during extrusion to prevent scratches during processing or transportation.
PMMA/PC/PETG Surface effect
Ensuring Quality and Precision in Vacuum Forming
At DitaiPlastic, we understand that choosing the right plastic sheet is crucial for the success of your vacuum forming projects. From considering material shrinkage rates to selecting the ideal textures, our expertise ensures that each step is optimized for the best results.
Whether you’re working with ABS, PS, PMMA, ASA, PC, PP, PETG, or PE, our team is equipped to provide tailored recommendations that meet your specific needs. We focus on precision, quality, and efficiency to deliver products that not only meet but exceed your expectations.
With a wide range of materials and textures available, we are your trusted partner for all your vacuum forming needs. Our commitment to excellence ensures that your project is handled with the utmost care, from initial consultation to final delivery.
Ready to start your next project? Contact us today to discuss your requirements and discover how DitaiPlastic can help bring your vision to life with our high-quality plastic sheets and expert vacuum forming services.