Thermoforming processes

Free forming

Free forming is a specialized thermoforming process for producing three dimensional plastic components without a forming counter tool. A thermoplastic sheet is selectively heated and then formed in a controlled manner, usually through controlled movement of a forming punch or defined air pressure.

The material follows the predefined contour freely in space without being clamped between two fixed mould halves. The result is large, low stress components with smooth transitions and high surface quality.

Advantages and applications of free forming

Thanks to the reduced tooling requirements, free forming offers a high degree of design freedom and enables the production of particularly large and complex curved components with efficient material usage. Uniform wall thicknesses and smooth transitions can be precisely controlled, resulting in low stress and dimensionally stable components.

As no closed negative mould is required, customized geometries can be implemented flexibly and modifications can be made quickly. This significantly reduces development times and tooling costs.

Typical applications of free forming include large design components, panels and covers with smooth radii, as well as three dimensionally curved elements for automotive, architectural and exhibition applications.

The process is also used for prototyping and small series production, as complex geometries can be produced economically without elaborate moulds. Free forming is particularly advantageous for visible components with high requirements for surface quality and design freedom.

GEISS offers thermoforming machines specifically designed for free forming, with precise temperature control and accurately adjustable motion sequences. The systems enable controlled, repeatable forming, even with large format plastic sheets.

With flexible process control and intelligent control technology, customized geometries can be produced efficiently. This makes the machines particularly suitable for demanding design components, prototypes, as well as cost effective small and medium series production.

A free formed roof window as a typical example of free forming.

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