Thin and Thick Gauge Thermoforming: What’s the Difference?

The thermoforming process involves heating a plastic sheet until it’s pliable, then placing it into or onto a mold to be formed with vacuum or pressure. But within this general description of the process, there is one key issue that can impact your part production: gauge.

With thermoforming, you can choose between thin gauge or thick gauge, depending on your application:

• Thin Gauge: Thin gauge thermoforming involves materials that are less than .060” thick to allow for greater flexibility. It focuses on creating very thin, usually disposable, plastic items such as plastic cups and packaging like clam shell containers.
• Thick Gauge: For studier, more rigid requirements, thick gauge thermoforming is used. It’s behind all sorts of different plastic components used in a variety of industries, from parts for a major appliance to those used on a jumbo jet.

Both types of thermoforming involve essentially the same steps; the main difference is in the result.

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