Thermoforming is a cost-effective way to manufacture relatively complex product shapes, as it does not require high temperatures or high processing pressures. However, it presents new challenges related to obtaining the desired thickness distribution. ANSYS solutions enable engineers to model temperature distributions, the application of stamps, the addition of a pre-blowing stage, deformation during the cooling stage and other factors that affect material thickness and uniformity. ANSYS technology also supports various mechanical tests such as top-load testing, compression, stretching and drop testing.

Simulation results for thermoforming medical device package: (top) finite element mesh automatically refined to capture mold curvature details, (bottom) predicted thickness distribution