High-Performance Thermoplastic Films (like Teflon™ Film)
We are experts in converting ultra thin (typical starting gauge range .003” – .060”), flat, high-performance thermoplastic films (like Teflon™ Film) into intricate custom three-dimensional shapes by utilizing the manufacturing process of thermoforming.
Below is a partial list high-performance materials (thin films) that we are experts in Thermoforming:
- Teflon™ FEP Film
- Teflon™ PFA Film
- Tefzel™ ETFE Film
- Vestakeep® PEEK Film
- Ultem® PEI Film
- Aclar® PCTFE Film
- Halar® ECTFE Film
Learn more about these and other high-performance materials that Welch Fluorocarbon can Thermoform.
Thermoformed Thin PEEK Component
Thermoformed Thin PEEK Medical Device Component
Thermoformed PEEK Medical Device Components
Thermoforming Advantages
Thermoforming has some unique advantages over other methods of processing plastics, such as injection molding:
- Parts are capable of having ultra thin walls (.001″) that can fit into tight spaces
- Precision tolerances
- +/- .002” for Thermoforming
- +/- .005” for trimming
- Rapid turn around time for proof of concept prototypes
- Optimal process for testing multiple materials during the prototype stage
- Low cost for prototype, pre-production and production tooling
- No weld lines
- Less susceptible to pinholes
Examples of End Use Applications
- Dielectric Properties / Insulation
Implantable medical device components for battery and capacitor insulation and chemical resistance.
An excellent alternative to Parylene Coatings. - Temperature Resistance
Perfect for applications that require high maximum use temperatures.
An excellent alternative or replacement for polyimide tapes, which are labor intensive. - Chemical Resistance
For applications that require a material that can stand up to the harshest environments. - Inertness
For applications that require a non-contamination / non-reactive material. - Releasability
For applications that require a non-stick or non-wettable material
Processes and Value Added Manufacturing
Our thermoforming manufacturing processes are extremely flexible and allow for a variety of application sizes including prototypes, pre-production, small production and large production annual blanket orders. All thermoforming processes are highly traceable, and Certificates of Compliance are available upon request.
Using a variety of innovative technologies, we are able to use precise manufacturing techniques to produce extremely complex custom components. Unique features that can be added to parts include:
- Notches
- Holes
- Slots
- Slits
- Multi plane trimming