Manufacturing Process
From A to Z (Design and Development)
Icon4 does much more than simply thermoforming plastic. Here is the short summary what steps we will go together to fulfil your request:
1. Design for Thermoforming
Icon4 team will work with you from your initial product design or even idea through completion. Knowing and having experience in thermoforming principles will maximize the benefits of plastic thermoforming and minimize cost and delays for your application.
2. Thermoplastic Material Selection
Thermoplastic material options are available that meet even the strictest requirements for strength, durability, impact and weather resistant of industries from mass transportation to medical device and industrial equipment. Icon4 has experience working with the top thermoplastic material suppliers, such as Heliopolis and will work with your team to select the specific thermoplastic material that meets the needs of your unique project.
3. Tooling Design and Construction
The mould or tooling is the foundation on which your part is formed. Proper tooling design and construction is essential to producing a high quality part. Icon4 will work with your unique design to create precise tooling to ensure that your parts are consistently of the highest quality and exact tolerances.
4. Thermoforming
Here is where your part really starts to take shape. Your mould is installed and calibrated into a thermoforming machine. The thermoplastic specifically selected for your application is heated to forming temperature and vacuum formed over the mould to create your part.
5. Trimming
Once your part has been thermoformed and has cooled, it will likely require trimming to remove excess plastic and add design features such as other cut-outs.
6. Assembling if needed
Once your part is formed and trimmed, Icon4 offers secondary operations such as installing attachments and hardware, bonding fixtures, and assembly of multi-part projects. These services reduce cost and lead time by consolidating your supply chain.
7. Finishing touches
If your part requires additional finishing and branding, Icon4 can apply color finishes, class A gloss finishes, and complex masking and branding to your parts.
