Thermoforming fluoropolymer tubing such as PVDF, PFA, PTFE, and FEP, offers unbeatable chemical resistance, high purity, and mechanical integrity, making it ideal for demanding sectors like chemical processing, medical devices, and semiconductor manufacturing.

But these benefits only hold if the forming process is done right.

Here are five common errors that compromise quality, reliability, and performance in custom thermoformed parts:

1. Choosing the Wrong Material
Selecting the right fluoropolymer is crucial to ensure long-term performance and dimensional stability.
PTFE, PFA, and FEP all offer excellent chemical resistance, but behave very differently under heat.

• PFA is the best all-rounder: high temperature tolerance, excellent chemical resistance, and strong shape retention due to low memory.

• FEP is easier to form at lower temperatures, but may lose shape over time.

• PTFE, while offering top-tier chemical resistance, is difficult to thermoform and tends to spring back to its original shape.

2. Using Incompatible Tooling
Fluoropolymers resist chemicals but are sensitive to surface contamination and thermal inconsistency. Poor tooling can cause blemishes or structural flaws.

Adtech uses custom-built, in-house tooling specifically designed for tube manifolds, containment bags, and instrumentation assemblies, ensuring precision without mechanical or aesthetic compromises.

3. Ignoring Material-Specific Forming Temperatures
Applying a one-size-fits-all heat setting often results in warping or poor definition.
Precise temperature control and even heat distribution are critical to maintaining quality.

4. Rushing the Cooling Phase
Rapid cooling can distort parts or reduce structural integrity.
Controlled cooling locks in both precision and performance.

5. Designing Without Thermoforming Limits in Mind
Deep draws, sharp edges, and non-uniform wall thicknesses can lead to thinning and mechanical failure.
Materials like PVDF and PTFE are less pliable than amorphous plastics, so formability must be factored in early.

Designs that use generous radii and consistent wall distribution—like heating coils or custom-shaped manifolds—achieve better strength and durability.

Bring Your Thermoforming Challenges to Adtech
Whether you're engineering retractable fluoropolymer coils or designing custom probe covers, Adtech brings decades of experience across all major fluoropolymers—PTFE, PFA, FEP, and PVDF.

Our bespoke forming processes deliver your specifications with precision, consistency, and the highest quality standards.

Find out more here

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