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Expertise

Thermoforming Heavy-gauge

The heavy-gauge thermoforming enables plates of 1 to 15 mm. This technology is suitable for sectors requiring parts with Strong rigidity, and High mechanical strength and a masterful finish. The significant thickness is ideal for body parts, guards, industrial equipment, or large-format elements.

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What are the advantages of heavy-gauge thermoforming for an industrial project?

The heavy-gauge thermoforming produces rigid, durable, and aesthetically pleasing parts, suitable for demanding environments and large formats.

The offers low tooling costs, great flexibility for all volumes. RBL Plastics operates this expertise on its Châteaubriant site, equipped with 10 five-axis thermoforming and cutting islands, capable of producing pieces up to 1800 × 2600 mm with great mastery and reliable repeatability.
thermoforming machine - RBL team
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Produce very robust parts

The process offers excellent mechanical resistance, ideal for intensive use and demanding environments.

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Reduce tooling costs

The moulds are simpler and less expensive than those of other technologies, which makes production more accessible.

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Get large formats

Thick-gauge thermoforming allows the production of large parts while maintaining good precision and a quality finish.

Thermoforming - Adjustment - RBL
Plastic thermoforming RBL
Thermoforming - Production Supervision - RBL

The 8 key steps heavy-gauge thermoforming

1 - Needs analysis and techno-economic proposal

Every project begins with a thorough analysis of your specification document. The functional aspects and the usage environment are studied to propose the most suitable thermoformed solution.

Following this detailed study, our design office formalises a Technical and economic proposal which is transmitted to you. This includes, in particular, the thermoplastic retained, the industrial constraints considered as well as the technical solution envisaged. It also includes an estimate of the required investment according to the volumes and the quality of finish required.

2 - Validation phase

The analysis of your needs, followed by a digital file validation phase which will be used for the production of the series. To do this, our design office can assist you by providing expert support on design subjects, particularly thanks to its mastery of SolidWorks.

3 - Design and manufacture of tooling

RBL Plastiques then designs the forming molds and cutting tools necessary for the project too called tooling. This ensures perfect consistency between the digital definition, the tooling and the desired plastic part.

Moreover, our in-house expertise in Tools and prototyping ensures great responsiveness and total mastery of development.

4 - Phase prototype

Following the study of the project and the digital design, the project is translated via the prototype production. Prototyping allows you to take the designed concept and refine it, bringing it to life for validation before starting the industrialisation phase.

It allows, in particular, to validate the mechanical outfit, The surface quality and finish of the part being considered.

5 - Qualification phase process

The qualification process phase is carried out before series production. For this, we mobilise the PPAP and APQP, two methods for to qualify all product and process specifications.

These include, in particular, the details of the industrial skills deployed and the different production phases that will enable series production.

This phase notably ensures stable and repeatable productions for subsequent stages, with a clear visualisation of the adopted production method.

6 - Series production

Following the study and qualification stages, RBL Plastics will support you in the series production. During this phase, the thermoformed parts are produced continuously, cut, packaged according to the characteristics of the qualification file drawn up during the process qualification phase.

RBL Plastiques thus guarantees consistent quality, a full traceability and a High industrial repeatability. The production draws on both Fine and thick-gauge thermoforming.

7 - Assembly of parts and sub-assemblies

Once the parts have been manufactured, these are assembled to form the simple or complex subsets. In this context, each piece is given a finish.

Ten Complementary components can also be integrated to Finalise sets (metal parts, inserts, fasteners, decorative trims).

8 - Control and dispatch

The parts are then packaged and dispatched via our supply chain in compliance with the customer's logistics plan, ensuring continuity of supply.

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Why call on RBL Plastiques for this expertise?

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Certified process

Certified ISO 9001 and 50001, we guarantee sustainable production that complies with industrial constraints.

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At the cutting edge of innovation

Through our research and development department, benefit from the latest innovations in thermoforming and plastic technology.

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A team of experts

We provide you with a team of experts and engineers from the design to the industrialization of your project.

# Industrialization
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We are replying to your questions

What thicknesses can be thermoformed?

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Heavy-gauge thermoforming allows for the conversion of plates from 1 to 15 mm, depending on the materials and the desired geometry.

Can we get a thick aesthetic part?

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Yes. Thanks to materials like’ABS and PMMA, It is possible to obtain a glossy, grainy or textured finish while maintaining high resistance.

Are large series compatible with this process?

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Yes. With 10 production islands and a multi-reference organisation, RBL Plastiques can produce significant volumes with great industrial stability.

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