Plastic parts are manufactured using various processing methods. In this article, we focus on comparing the processes of plastic thermoforming and 3D printing.
Amin Lakhal
Updated on June 3, 2026
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In thermoforming, also known as plastic deep-drawing, thermoplastic plastics are formed by heating using thermoforming machines. After cooling, the desired shape is cut by punching or milling.
This is how the process of thermoforming plastics works:
3D printing definition: 3D printing, also known as additive manufacturing (AM), begins with the creation of a digital 3D model, which is divided into thin horizontal layers - a process known as "slicing". The 3D printer then builds the object layer by layer by applying material such as plastic.
The 3D printing process was invented in the early 1980s and has therefore existed for about four decades. Originally, 3D printing was a slow and expensive manufacturing method. However, thanks to extensive technological developments, 3D printing technology has evolved into a process that finds applications in various industries.
3D printing is a versatile plastic processing method, which in turn can be divided into several printing processes. Three important ones are the following:
In this 3D printing process, a laser selectively fuses plastic powder particles. This creates a three-dimensional component layer by layer. One advantage here is that the residual powder can be reused.
3D printing process with SLA: A laser is used here and cures the part from liquid resin. This process offers the highest precision, but limited material selection.
The printing material required for this is heated in the 3D printer and the object is built up layer by layer along the path. Once printing is complete, support structures or support materials must be removed from the object, if present.
Here is a simplified breakdown of the FDM 3D printing process:
Thermoforming and 3D printing are two completely different processes for manufacturing plastic parts. While thermoforming is mainly used for series production, 3D printing is primarily suitable for prototypes and small series.
| Factors | Thermoforming | 3D Printing |
|---|---|---|
| Volume | Medium > 5 | Low < 5 |
| Lead time | Weeks | Days |
| Tooling costs | Medium | No tooling needed |
| Tolerances | - | -to++ |
Thermoforming proves to be an extremely cost-effective option, even when producing large volumes. This is partly due to fast and cost-effective production, low tooling costs, high material efficiency and flexible shaping. The large selection of materials, additives and surface finishes of the semi-finished products also make thermoforming an extremely attractive solution in various industries.
The disadvantage - depending on the series size - lies in the necessary investment in a tool.
| Advantages of thermoforming Disadvantages of thermoforming | Disadvantages of thermoforming |
|---|---|
| Low investment costs for tools | Tool adjustments can be expensive |
| Cost-effective production | Potential sources of error in semi-finished product manufacturing due to frozen stresses in the material during extrusion |
| Worthwhile even for small quantities | Complex shapes with very thin walls are limited |
| Optimal options for post-processing | Potential difficulty in achieving uniform material thicknesses in complex shapes |
| Post-industrial recycling possible for simple cycles | One-sided material contact |
| Unrivaled for thin-walled parts | More complex geometries cannot be produced using 3D printing |
| Short lead times | Semi-finished products more expensive than with 3D printing |
| Large selection of materials | Cutting and punching costs |
| All sizes and shapes possible (large parts) | Complex geometries that cannot be produced using 3D printing |
3D printing is particularly suitable for the production of complex prototypes and small series. However, compared to thermoforming, it also brings some limitations.
3D printing enables the production of complex, customized parts with high precision and minimal material waste or material scrap. This leads to material and cost savings for smaller volumes or prototype development. In addition, the need for expensive molds or tools for production is eliminated, which reduces the initial investment.
3D printing is generally slower and less cost-effective when producing large volumes. The limited material selection and strength can also mean that 3D printing is not suitable for all applications. In addition, due to the layer structure of the parts, time-consuming post-processing may be necessary, which requires time and resources.
In comparison, a thermoformed part can often be used without additional grinding, polishing or painting work. The appropriate finish can be achieved directly with the material or by introducing an imprint of the desired surface structure in the tool.
| Advantages of 3D Printing | Disadvantages of 3D Printing |
|---|---|
| No tooling costs | Low quantities |
| Short delivery times | Slow manufacturing process |
| Complex shapes possible | Limited material selection |
| No long setup times & tool changes | Surface may require post-processing |
| No tool adjustments | Component size limited |
| Constant price per part | Manufacturing process is more prone to errors, especially with complex components |
| Shortened production time for prototypes | Slightly larger manufacturing tolerances |
| / | Low material efficiency → necessary support structures |
The 3D printing process offers diverse application possibilities, ranging from prototype development to the production of customized medical implants. The process is particularly suitable for flexible small series that can be implemented without tooling costs.
3D printing is particularly suitable for the cost-effective production of small series, as expensive tools are not required. This is particularly advantageous for companies that need flexible and demand-driven production of construction or spare parts. In addition, 3D printing technology is ideal for producing detailed samples and models, especially in industries such as design and architecture, where realistic models are of great importance for planning and visualization.
In healthcare, 3D printing enables the production of customized medical elements that can be precisely tailored to the individual characteristics of a patient. This increases the success rate of implantations and minimizes the risk of complications.
In various industries such as mechanical engineering or automotive, 3D printing is used to produce customized spare parts. This enables efficient production of components, especially for models where conventional manufacturing methods may no longer be economical.
The thermoforming process has been an established production method for transport packaging, housings, covers and blisters for decades. It is characterized by high formability, low tooling costs and fast cycle times.
In the automotive sector, thermoforming is the preferred method for plastic trays.
In industrial use, thermoformed plastic parts are used for a variety of applications, including:
Plastic tubs and containers are also widespread, e.g. for chemicals, liquids, as potting molds or for transport through industrial washing systems.
Thermoformed parts with ESD protection prevent damage to sensitive electronic components.
In conclusion, the comparison of thermoforming and 3D printing shows that both technologies have specific strengths and weaknesses that should be considered depending on the requirements of a project or product.
3D printing is primarily suitable for creating short-term prototypes and very small quantities. Thermoforming proves to be a cost-effective option for medium to large volumes. In addition, thermoforming offers fast production costs, comparatively low tooling costs and material efficiency, as well as broad material requirements.
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Thermoforming is suitable for cost-effective series production of large plastic parts with flexible shapes, while 3D printing is ideal for prototypes, small series and complex components without tooling. Thermoforming is faster for large volumes, 3D printing more flexible for customized parts.