Pressure Forming Plastic: The 10% solution.

Pressure forming plastic means startup tooling costs as low as 10% of that required for the same injection molded project!

That's more than a claim; it's documented fact. 10% of the cost...a 90% savings. Any way you look at it, it's a strong argument for considering pressure forming for your next molding project. Add to that enormous cost savings a turnaround time of just 20% of injection molding...together with quality that rivals injection molding for finite detail and crispness...and it's easy to see why pressure forming has become one of the hottest molding processes of the nineties.

As with other thermoforming processes, pressure forming begins by heating a sheet of material to a point that's malleable enough to be shaped. The process accepts almost any thermoform-rated material, and we can work with sheets up to 6 X 16 feet. Therefore, we can shape components of virtually any size.

After the material is heated to the correct degree of flexibility, it's formed to the desired shape over a high quality, precision-tooled mold which can be designed with incredible detail, including undercuts and reverse drafts. When the material is in place, air is evacuated from the sealed space between the sheet and the mold. At the same time, extremely high air pressure is applied to the outside of the material as it is formed to the mold. Not a centimeter of material nor a single detail of the mold escapes that high pressure treatment. That ultra high pressure applied to the soft material is what helps the pressure forming process deliver such extremely accurate, detailed molding completely faithful to the original design.

When the formed part is removed from the mold, it progresses through a series of fully automated secondary operations. Edges and trim are smoothed to perfection with precise CNC routers; slots and grille work are added as needed; bosses, ribs and special fastening devices are permanently bonded; silk screened logos and other accouterments are added. But the most demanding step in the process is left till last: A rigorous inspection in Grimm Brothers' own Quality Control department, an uncompromising process which accepts nothing less than absolute perfection.

Pressure forming provides a manufacturer with these benefits:

• Startup tooling costs typically as little as 10% of comparable injection molding tooling.
• Extremely fast turnaround time, with production tooling commonly completed in six to eight weeks and the first completed parts ready to ship within one to two weeks following approval of the finished tooling.
• Easily modified tooling to accommodate revisions to part specifications.
• Highly cost efficient production runs of 50 to 5,000 units, or higher, depending on the size and complexity of the component part. The cost and affordability of running these small quantities also allows the manufacturer to maintain a leaner inventory and schedule more frequent runs.
• Broad material flexibility which allows the use of several different thermoformable materials from .060 to .500 gauge with virtually unlimited size restrictions.
• Complete aesthetic integrity. Properly pressure formed materials look as good or better than injection molded items with sharp edges, tight corner radii and ultra-fine detail.