Twin Sheet Thermoforming

Providien has been a world-leading thermoformer of highly aesthetic, complex medical device enclosures and other plastic products for over 40 years. These decades of experience have helped to make Providien a trusted and competent source for your company’s twin sheet thermoforming needs.

What is Twin Sheet Thermoforming?

In the twin sheet thermoforming process, two separate sheets of material are heated simultaneously. One sheet is drawn into a top tool and the other sheet is drawn into a bottom tool using a vacuum process. The tools are then brought together and pinched around the perimeter of the part. Forced air is applied between the sheets, pressing each sheet into its respective tool resulting in a hollow part that is structurally rigid and cosmetic on both sides.
Parts that need to be controlled and/or cosmetic on both sides are ideal candidates for this process. Doors, panels and lids are great examples of these types of parts. An additional benefit of is that they dampen noise and due to the trapped air cavity; can act as a thermal insulator.


Twin sheet thermoforming has significant advantages over competitive plastic processes and single walled parts. Some of these advantages are as follows:

  • Ability to control both sides of the part
  • Formed-in threaded inserts are common with twin sheet parts as they increase repeat-ability and reduce cost by eliminating the need for bonded bosses
  • Provides a structurally rigid part that is hollow – excellent strength to weight ratio
  • Lower tooling cost than competitive processes
  • Large parts- Providien can twin sheet form parts up to 5’ x 8’
  • May use different starting gauge material depending on draw depth to control costs
  • Allows for formed in ribs or other structural elements to strengthen the part
  • Variety of material choice – including Acrylic/PVC, PC/ABS, ABS, HIPS among others

Types of Products that Can Be Produced

This process can be used to manufacture a number of different types of products, some of which may include foam-filled products, single or dual-colored products, multi-textured products, air ducting, wiring ducting, hollow-formed products, and products with various degrees of thickness.
This method of thermoforming offers a wide range of benefits for producing a vast number of types of products for companies. Providien’s long history of producing plastic products in this way means a quality product for your company every time. Contact Providien today to learn how we can fulfill all your company’s needs.