Twin Sheet Forming is a process in which two sheets of thermoplastic material are vacuum formed at the same time in the same machine, producing a single welded part. 

The sheets are heated to the correct forming temperature and are then transferred to the vacuum forming molds. Any entrapped air between the hot plastic sheet and the mold is removed to create a vacuum that holds the sheets against the mold surfaces. While the sheets are still hot the molds are pressed together, creating welded joints where the plastic sheets contact one another. After cooling and de-molding, the part is ready for any trimming and or secondary operations that are necessary to produce the final product.

The tooling required for twin sheet forming is typically produced from aluminum.

The advantage of this process is that 2 hot sheets of plastic can be formed and welded together in a single operation. This gives the designer the ability to create hollow parts. Structural parts can also be produced by designing formed hollow profiles into the finished part.

For images of our thermoformed products, please look over samples of previous projects on the Photo Gallery page. For additional information, please give us a call at 1-510-569-6465, or use our online Request Information form.