Match-Metal Trimming: Precision for In-Line Thin Gauge Thermoforming

Thermoforming doesn’t stop at forming. For many projects, precision trimming is what transforms a formed sheet into a usable, functional part. At Tru-Form Plastics, our horizontal trim press with canopy takes thin gauge thermoforming to the next level. Integrated directly with our in-line thermoforming process, the press uses match-metal tooling to trim parts with speed, accuracy, and repeatability. Since its addition in 2021, it has expanded our thin gauge capacity for customers with demanding volume and tolerance requirements.

In-Line Trimming for Greater Efficiency

The horizontal trim press trims parts directly from the continuous sheet as it exits the thermoforming line. Instead of relying on secondary trimming operations, parts are cut in-line through a hardened punch-and-die system. This approach eliminates added handling, reduces production steps, and produces parts that meet tight dimensional requirements right out of the press.

Unlike conventional Steel Rule Die (SRD) trimming, which has limitations in alignment and feature complexity, match-metal trimming achieves multi-level precision at high speed. It allows for intricate cut features and geometries that would otherwise be out of reach with standard trim dies.

Why We Invested in Match-Metal Trimming

The decision to add this capability came from customer demand. Projects increasingly required faster cycle times and tighter tolerances. By investing in the horizontal trim press, Tru-Form gained the ability to deliver consistent, repeatable results on high-volume jobs where even minor deviations in trimming could create costly setbacks.

Built for High-Volume Performance

The trim press can accommodate nearly any size part or material that runs on our in-line thermoforming machines. While versatile, its greatest value comes in higher-volume programs where the investment in match-metal tooling is offset by faster throughput and long-term tool durability. Industries such as medical and electronics benefit most, where accuracy, repeatability, and speed are essential.

Advancing Quality and Reducing Scrap

Match-metal dies are manufactured from hardened steel and ground for precision, which gives them both accuracy and longevity. That translates into clean cuts, extended tool life, and fewer quality concerns over time. For our customers, the result is reliable repeatability across production runs.

Efficiency also improves. The press supports faster cycle times and better material usage, reducing scrap by allowing for optimized cavity layouts. Finished parts exit the press already nested and ready for downstream handling or packaging, saving time and labor.

Seamless Integration with Other Capabilities

The horizontal trim press complements the broader set of capabilities at Tru-Form Plastics. Together with in-house tooling, CNC trimming, and assembly services, it enables customers to scale projects smoothly from prototype to high-volume production. Thin gauge jobs that require both complexity and speed benefit most from this integration.

Solving Unique Challenges for Customers

One project highlights the value of match-metal trimming. A medical customer needed a polypropylene tray with a vertical trim feature that would create a living hinge to secure a paper document inside the package. Several leading thermoform die makers declined the opportunity, citing the feature as unachievable in thermoforming. Tru-Form approached the challenge differently, collaborating with a die maker from the metal can industry. Together, we engineered a solution that delivered the hinge feature exactly as required. The success of this project demonstrated both the flexibility of match-metal tooling and our willingness to find answers where others said none existed.

Strengthening Market Position

Not every thermoformed part requires match-metal trimming, but for those that do, the benefits are significant. For customers with high-speed, high-volume programs, our horizontal trim press provides capabilities that support tight tolerances, complex features, and scalable production. It reinforces Tru-Form Plastics’ position as a dependable partner for thin gauge thermoforming projects that demand both precision and throughput.

Let’s Talk About Your Next Project

High-volume trimming doesn’t have to compromise accuracy. With in-line match-metal trimming, Tru-Form Plastics delivers repeatable quality at speed for industries that require it most. If your next project calls for faster cycles and higher trim precision, connect with our team today.