What Is Pressure Forming?

Ever seen plastic parts with sharp details and sleek textures? They might be pressure formed.This process creates high-quality plastic products. It is faster and cheaper than injection molding.In this article, you’ll learn what pressure forming is. Discover how it works and why industries love it.

What Is Pressure Forming?

Pressure forming shapes heated plastic with air pressure. It creates highly detailed plastic parts.This method is an advanced type of thermoforming. It uses much more force than vacuum forming.Up to five tons of air pressure push the plastic. This force makes sharp details and textures possible.

How Does Pressure Forming Work? (Step-by-Step)

Step 1 – Insert plastic sheet into pressure forming machine

A plastic sheet is placed over a mold. This mold is called a template.

Step 2 – Heat the sheet to forming temperature：The machine heats the plastic until soft. This makes it ready for shaping.

Step 3 – Apply air pressure to press the sheet into the mold：Pressurized air pushes the sheet down. It forces the plastic into every detail.

Step 4 – Cooling and part removal：The part cools and hardens quickly. Then, workers remove the finished piece.

Pressure Forming Mold Types

Male mold vs. Female mold
Molds come in two main types. Male molds are convex shapes. Female molds are concave.

• Male molds form a part's inner dimensions.

• Female molds control the exterior surface.

Female molds are preferred for pressure forming. They give the best detail and texture.

Benefits of Pressure Forming

Achieves injection-molding-like aesthetics
You get crisp textures and sharp logos. The surface detail is very high quality.

Lower tooling cost than injection molding

Tooling can be up to 90% cheaper. This saves a lot of money.

Faster time-to-market
Molds are ready in just weeks. This is much faster than injection molding.

Ideal for small & medium production runs

It is perfect for limited quantities. You do not need huge orders.

Undercuts & deep-draw capability
It can make complex, deep parts. Vacuum forming often cannot do this.

Pressure Forming vs Vacuum Forming

Pressure Forming vs Injection Molding

Pressure Forming Materials

Many plastics work with this process. Each material has special strengths.

• PETG: Food-safe and strong.

• ABS: Tough and impact-resistant.

• PC: Durable and lightweight.

• Acrylic (PMMA): Clear and protective.

Choose your material based on your needs:

• Impact resistance

• Paintability

• UV or chemical resistance

• Desired texture and finish

Common Pressure Forming Applications

This process is great for many products.

Industrial / Robotics / Electronic enclosures
It makes strong, detailed covers for machines.

Medical equipment housings
Housings need to be durable and easy to clean.

Consumer electronics bezels
Bezels for displays look sleek and professional.

Automotive interior panels
Dashboards and door panels have sharp styles.

Design Considerations for Pressure Forming

Follow these tips for the best parts.

Draft angles
Add a slight angle to the walls. This helps remove the part from the mold.

Corner radii
Avoid sharp corners. Use rounded edges instead.

Undercuts & deep draws
You can design complex shapes. But talk to your manufacturer first.

Holes & cutouts designed into tooling
Add holes directly into the mold. This reduces extra work later.

Selecting a Pressure Forming Manufacturer

Look for a partner with these qualities.

• In-house tooling: They design and make molds themselves.

• Post-forming capabilities: They can paint, assemble, and finish parts.

• ISO certification: They follow strict quality standards.

• Industry experience: They know your product's needs.

FAQ (Add Long-Tail SEO Keywords)

Is pressure forming expensive?
No, it is often very cost-effective. Tooling costs are much lower than injection molding.

Can pressure-formed parts replace injection molding?
Yes, for many applications. It is ideal for medium volumes and large parts.

What shapes are not suitable for pressure forming?
Avoid parts needing fine detail on both sides. Injection molding is better for that.

What is the typical lead time?
Tooling can be ready in six to ten weeks. This is much faster than other methods.