Twin-sheet molding (also known as twin-sheet thermoforming) is a specialized manufacturing process used to create large, hollow plastic parts by simultaneously heating and forming two separate plastic sheets in matched molds, then fusing them together under pressure.
Not all thermoforming operations are equipped to handle twin-sheet work; it demands significant expertise and infrastructure beyond conventional single-sheet forming. That’s why D.P. Riggins has for more than 25 years partnered with one of the most comprehensive thermoforming manufacturers in North America … with the machinery, experience and infrastructure that extends well beyond conventional single-sheet forming.
For OEMs, twin-sheet thermoforming allows for more complex geometries, internal structures and, most importantly, enhanced strength-to-weight ratios. It’s ideal for applications requiring lightweight yet rigid components, such as panels, enclosures or cases, with integrated features like insulation channels or mounting bosses.
Twin-sheet thermoforming is a more complex and capital-intensive process. It requires precise timing, advanced equipment and custom tooling to align and bond the sheets correctly.