
How It’s Made at Altrum | Thermoforming Acrylic
May 14, 2025, In How It's Made at Altrum
How It’s Made at Altrum | Thermoforming Acrylic
At Altrum, we use a variety of advanced techniques to create stunning deal toys and awards. One of the most exciting and versatile methods we employ at our Canadian factory is thermoforming with acrylic! This process allows us to shape acrylic sheets into custom, three-dimensional designs with precision and efficiency. Whether it’s replicating an object like a construction hard hat or crafting a unique shape, thermoforming is a fantastic option that minimizes material waste while delivering high-quality results.
What is Thermoforming?
Thermoforming is a process where a thin sheet of acrylic is heated until it becomes pliable, then molded onto a 3D object using vacuum suction. Once cooled, the acrylic hardens into the desired shape, creating a lightweight yet durable piece that maintains crisp details!
The Thermoforming Process
Our thermoforming machine follows a carefully controlled process to ensure a flawless final product:
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Heating the Acrylic Sheet – A thin sheet of acrylic is placed at the top of the thermoforming machine. There, it gradually heats up under the machine’s specialized heating coils. This controlled heating ensures the acrylic becomes soft and flexible without overheating or warping.
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Molding the Shape – Once the acrylic sheet reaches the optimal temperature, it is quickly lowered onto the mold platform, which contains the 3D object—such as a resin-printed hard hat. A vacuum system then removes all the air, pulling the softened acrylic tightly around the object and creating an exact mold of its shape.
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Removing the Mold – After cooling and hardening, the molded acrylic is carefully separated from the original 3D piece. The result is a perfect acrylic mold, ready for use in deal toy or award production.
Why Choose Thermoforming for Deal Toys & Awards?
Thermoforming offers several advantages that make it an excellent choice for creating custom elements in deal toys and awards:
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Reduces Material Waste – Unlike solid acrylic blocks or casted designs, thermoforming requires only a thin sheet of acrylic, making it a more sustainable and cost-effective option.
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Lightweight Yet Durable – Thermoformed acrylic maintains structural integrity while remaining significantly lighter than solid acrylic alternatives.
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Highly Customizable – This method allows for intricate shapes and unique forms that would be difficult or expensive to achieve with other fabrication techniques.
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Efficient & Scalable – Thermoforming enables us to produce multiple identical pieces with precision, making it ideal for projects that require consistency and efficiency.
Elevate Your Designs with Thermoforming
Thermoforming acrylic is a game-changer for those looking to incorporate 3D elements into their deal toy or award while maintaining a sleek and polished look. At Altrum, we take pride in utilizing this method to bring our clients’ creative visions to life with efficiency and sustainability.
Interested in using thermoformed acrylic for your next deal toy or award? Contact our team today to learn more about how this technique can enhance your project!
How It’s Made at Altrum | Thermoforming