Process comparison
Twin-sheet forming vs Blow molding
Both make hollow parts. Twin-sheet thermoforming forms two sheets and fuses them into a double-walled part; blow molding inflates a molten tube into a container. Wall control and part type differ.
Twin-sheet forming vs Blow molding — side by side
| Twin-sheet forming | Blow molding | |
|---|---|---|
| Wall control | Each wall formed independently | Wall varies around the blow |
| Part type | Flat-ish hollow parts, pallets, ducts, cases | Bottles, tanks, containers |
| Different faces | Two different tools / textures possible | Single continuous wall |
| Tooling cost | Moderate | Moderate to high |
| Best volume | Low to medium | High |
Choose Twin-sheet forming when…
- Double-wall pallets, ducts, panels and cases
- Each face needing its own shape/texture
- Strong, stiff hollow parts at moderate volume
Choose Blow molding when…
- Necked bottles and closed containers
- High-volume hollow packaging
- Thin, light hollow vessels
The verdict: Twin-sheet forming makes strong, double-walled parts with independent faces — pallets, ducts, cases; blow molding makes necked hollow containers at volume.
Frequently asked
What is twin-sheet forming?
Two heated sheets are formed simultaneously and fused at the edges into one hollow, double-walled, rigid part.
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