AMR Future Brief| Analyzing the Evolution of Vacuum Forming Technology and the Trends Influencing it in 2024

Vacuum forming, also sometimes called thermoforming, is an industrial process used to mold plastic into desirable forms and shapes. As the name suggests, the process involves heating the plastic till it becomes pliable and using vacuum to give it a shape as per the requirement. Vacuum forming is a quite common process used in various end-use industries due to its affordable and flexible nature. For example, various components used in automobiles such as floormats, bumpers, car seats, truck beds, etc., are manufactured using thermoforming techniques. Subsequently, this technique is used to manufacture many consumer goods and household products like packaging items and cleaning accessories.?

Robotics and automation transforming the field of vacuum forming?

Due to the wide applicability of this technique in several industries, different types of vacuum-forming machines have been built over the years. DIY machine is one such example used in small-scale production of plastic molds. It is the simplest of all the machines and is used for manufacturing goods like toys, stationery items, and other household products. On the other hand, tabletop thermoforming machines manufacture items from acrylic and polymers. Hence, these machines feature in automotive manufacturing and aerospace industries wherein polymer-based and PVC components are widely used. The other two commonly used vacuum forming technologies are single-heater and double-heater machines which are quite advanced and utilized for making complex equipment and tools like medical apparatus, industrial hardware, electronic goods, etc.?

However, there are certain issues with these traditional techniques of plastic molding; while these conventional methods produce good results, they are highly inefficient and consume a lot of power. Most of the manufacturing methods mentioned above require a large amount of raw plastic and result in huge wastage during different processes. To tackle this issue, many plastic manufacturing companies have integrated robotics and other automation technologies to bring down the wastage and increase the productivity of these machines.??

For instance, in July 2024, Summit Protech, a plastic material handling solutions developer, announced the launch of a new range of automation robots to increase efficiency and precision in molding applications. The automation robots are designed to provide high-speed operations, ensure accurate component placement, and adapt to a wide range of molding tasks. Moreover, these robots can easily integrate with the existing vacuum forming machines and reduce the time required for installation and setup. Automation robots, like those developed by Summit Protech, can significantly reduce human error and minimize wastage, thereby bringing down the input cost and increasing the profitability of the business.?

Increasing shift toward advanced composites and sustainable materials?

Plastic pollution has recently become a serious issue, causing major harm to marine and land ecosystems worldwide. An environmental study jointly conducted by various non-governmental organizations found that the formation of the Great Pacific Garbage Patch is the result of the accumulation of microplastics emanating from plastic water bottles and other food packaging items. The study resulted in a massive outcry among environmentalists and policymakers across the globe leading to several laws being passed in different countries banning plastic materials.?

As a result of the rising awareness regarding the hazards of plastic pollution, a major change witnessed in the vacuum forming plastic industry is the increased use of advanced composites and biodegradable materials in place of conventional plastics. Compounds like polybutylene adipate terephthalate, polyetheretherketone (PEEK), polyhydroxybutyrate, etc., which are classified as biodegradable plastics, are now increasingly being used as raw materials for manufacturing different household items.?

At the same time, industries using vacuum forming methodologies for plastic molding are also installing closed-loop recycling units where waste materials can be collected, reprocessed, recycled, and then reused as raw materials for manufacturing different products. In November 2023, Coveris, a medical packaging materials manufacturer, announced the launch of Formpeel P, a recyclable thermoforming film for packaging medical products and devices. The film is transparent, has low shrink-back properties, and offers high-quality forming characteristics which makes it a suitable choice for medical equipment and tools. With a recyclability of more than 90%, Formpeel P film has become a popular solution in the biomedical packaging industry .?

Along with the use of biodegradable plastics and sustainable materials, another major trend witnessed in the industry is the development of energy-efficient machines for thermoforming processes. For instance, companies manufacturing heavy industrial machinery have recently developed infrared heating systems that heat plastic sheets efficiently and uniformly, thereby reducing the power usage required for vacuum-forming processes. In April 2024, Arburg, a leading machine manufacturing company based in Germany, launched an injection molding technology that can be used for manufacturing products like recyclable plastic cups. The company has claimed that the technology is much more efficient than traditional vacuum forming techniques as it helps in resource-saving and no stamping waste is produced.?

In summary?

To conclude, vacuum forming, over the years, has become highly popular as one of the easiest and most flexible techniques to manufacture a wide range of plastic products. The widespread applicability of this technology in various end-use industries like consumer goods, food packaging, healthcare, and automobile manufacturing, has improved the growth rate of the vacuum forming plastics industry. Furthermore, the integration of robotics and automation in manufacturing processes is expected to take the sector to new heights in the coming period. The rising shift toward sustainable materials and energy efficiency is anticipated to create new investment opportunities in the landscape in the near future.?

For a detailed analysis of the recent developments and upcoming trends in the vacuum forming plastics industry,?contact us , today!??

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? **?????????????? ????????????: Akhilesh Prabhugaonkar ?

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