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Thermoforming
Overview
Big Bear specialise in the production
manufacture of large and medium-
sized thermoformed parts in single-
sheet, twin-sheet and pressure
forming technology.
Moulding
UK’s largest single and twin sheet
rotary moulding machines -
up to 3.5m x 2.5m x 1.2m.
Moulding
Machining and Trimming
Assembly, Clean & Pack, Delivery
Material Selection
Big Bear has experience with a
wide variety of thermo-plastic
materials enabling us to advise
customers on the best material
selection for their product.
Airline Seat Backs
Concept and Styling
.
Big Bear
History of Thermoforming
Twin Sheet
Advantages / Disadvantages
Disadvantages:
• Higher production part costs compared to injection
moulding due to sheet extrusion, trimming and trim
waste.
• Trim waste can be granulated and re extruded.
Advantages / Disadvantages
Advantages:
• Low tooling costs compared to injection or
compression moulding or processes.
• Tooling can be tailored to type & volume of parts
required.
• Ability to mould different thicknesses, colours & types
of materials when developing products.
Advantages / Disadvantages
Advantages continued!
• Ability to try different techniques at development
stage before committing to production tooling.
• Ability to mould very large parts which are very
difficult and expensive to produce with other
moulding processes.
Tools for Vacuum-Forming
• Quick to produce vs. higher volume applications e.g.
steel tooling for injection moulding.
• Timber, MDF & Ureol can be used for very low volume,
prototype / development parts.
• For higher volumes, temperature controlled aluminium
tools are ideal.
Thermoforming Applications
Applications
Applications
Applications
ABS
Foil-Laminated ABS
PMMA - ABS
Polyolefins
• HDPE
• MDPE
• PP
• TPE
Acrylonitrile Butadiene Styrene
Bearex Bumpers
Bearex Bumpers
Warwick Sub
Warwick Sub
Warwick Sub
Innovation Award – 1st Place
Warwick Sub
“…The collaboration with the specialists at Big Bear
has been hugely beneficial and successful. To very
tight time constraints, a student-designed, complex
hydrodynamic nose-cone has been produced,
overcoming significant manufacturing difficulties to
produce an excellent result…”
Dr Ian Tuersley, Project Director
Anti-Microbial Materials
Bio-Plastics
Emma Hockley, Big Bear Plastics, Thermoforming and Materials

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Emma Hockley, Big Bear Plastics, Thermoforming and Materials