Analysis of Thermoforming Process and Industrial Practice of RAYSHAPE

The essence and advantages of thermoforming process
Thermoforming is an advanced manufacturing process that heats the pre-extruded plastic sheet to a plastic state, forms it into a specific shape through a mold, and then obtains the final product through precision trimming. Different from injection molding that requires melting plastic, the core of the thermoforming process lies in the secondary processing of solid sheets. This feature brings three major industrial advantages:

60% reduction in mold cost (especially suitable for large parts)
Advantages in the production of thin-walled products (the thinnest can reach 0.15mm)
40% reduction in energy consumption (compared with injection molding)

As the core technology field of Wenzhou Rayshape Machinery Co., Ltd., we have been deeply engaged in the research and development of thermoforming equipment for more than ten years, and continue to promote the innovation and breakthrough of this technology in the production base of Pingyang Binhai New District.

Analysis of the core technologies of the three stages of thermoforming

1. Precision heating control
Rayshape uses a multi-zone independent infrared radiation system to break through the limitations of traditional heating:
Intelligent matching of wavelength and material absorption spectrum (patented technology)
A-PET/R-PET/PLA and other materials achieve ±1℃ temperature control accuracy
Temperature difference in thickness direction ≤3℃ (eliminating internal stress)

2. Composite pressure molding technology
Rayshape's patented positive and negative pressure composite molding system achieves:
Vacuum preforming (0.09MPa adsorption to ensure basic contour)
High-pressure precision molding (0.8-2.5MPa air pressure to shape fine features)
Pre-stretching plug auxiliary technology (wall thickness uniformity increased by 90%)

3. Intelligent trimming process
Integrated online laser cutting system:
CCD visual positioning accuracy ±0.05mm
Heat-affected zone ≤50μm (to ensure the integrity of brittle materials such as PLA)
Automatic recovery rate of edge materials ≥95%
Ruisu Machinery Product Matrix and Industrial Application
Relying on ELEMOTION's technical accumulation, we provide a full range of thermoforming solutions:

1. Multi-station positive and negative pressure molding machine
Six-station rotary design (core equipment for medical packaging aseptic production line)
Molding-cooling cycle shortened to 8 seconds (ISO 13485 certified)
Suitable for high-precision products such as medical devices

2. Double-piece thermoforming system
Infrared melting edge real-time monitoring technology (fusion strength ≥25N/mm²)
Automobile air duct integrated molding (replacing traditional adhesive process)
Special solutions for hollow structural products

3. Fully automatic serial production line
Sheet extrusion-molding-stacking full process integration
OEE (overall equipment efficiency) ≥ 88% (core of unmanned workshop for food packaging)
Comply with BRCGS global food safety standards
Rayshape's digital manufacturing ecosystem
As an intelligent manufacturing entity under ELEMOTION, we have built a three-in-one technology system:

Cloud process library
Accumulate 5000+ material parameter solutions (covering BOPS/PVC/bio-based materials), support global equipment parameter synchronization

Predictive maintenance system
Vibration sensor network achieves 400-hour fault warning
Thermal balance module life prediction error ≤ 5%

Digital twin factory
In the new energy vehicle battery tray project:

Virtual commissioning shortens the trial production cycle by 70%
Molding stress simulation accuracy reaches 98%
Sustainable development practice
Practicing green manufacturing at the Pingyang production base:

Energy recovery system captures 85% of braking kinetic energy
Closed cooling cycle achieves zero wastewater discharge
Blockchain traces the proportion of R-PET raw materials (real-time display of customer dashboard)

"Rayshape PLA-specific machines reduce the carbon footprint of biodegradable lunch boxes by 42%”

——Preview Rayshape product PDF

Corporate mission and technical commitment
Wenzhou Rayshape Machinery Co., Ltd. is located in Binhai New District, Pingyang County. As a core manufacturing enterprise under Yudong Holding Group, we adhere to the concept of "technical advancement and innovation":

Possessing a number of core patented technologies for thermoforming
The R&D team has been deeply involved in the field of plastic molding for more than 15 years
24-hour remote operation and maintenance system covers global customers
Through continuous iteration of positive and negative pressure composite technology and deepening of AI defect prediction algorithms, we deliver not only equipment, but also a plastic molding ecosystem covering digital factory planning, material science support, and full life cycle management.

Technical consultation: +86 15355870907 | Smart solution official website: https://www.cnrayshape.com/