What does your plug do for you?

More than 90% of all thin-gauge thermoformed parts are formed with plug-assisted pre-stretching. In this whitepaper, we outline general principles and best practices for using HYTAC® syntactic foams in thin-gauge thermoforming applications. While specific plug designs are dictated by many factors including depth of draw, the number of mold cavities, the critical nature of the wall thickness and the stretching characteristics of the plastic, there are certain fundamental techniques that can help improve the repeatability of the forming process as they relate to the plug assist. We offer a 5-step process to help toolmakers and thermoformers get the most out of the humble plug.