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Thermoformed Wall Thickness Uniformity

Parts thermoformed from an extruded thermoplastic film will exhibit tapering in the wall thickness when thermoformed. This makes sense when you consider that you start with a flat film that has a uniform thickness, heat it, and then form it into the mold geometry using pressure, typically supplied by vacuum. The degree of tapering and gauge loss will be different with each mold geometry.
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Stress in Thermoplastics

When you melt and “work” a plastic resin at or above its crystalline melt temperature, like in extrusion, the plastic resin likes to remember the physical torture it was put through as it is then cooled quickly. Depending on the type of plastic resin that memory can be large amounts of stress.

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