How to Choose the Right Plug-Assist Material

A question that we get asked a lot is, “What type of syntactic plug material should I use for my application?” Like most things in thermoforming, the answer is, “It depends.” However, we recognize that thermoformers and toolmakers want some degree of certainty when choosing plug materials. That’s why we have created a selector guide to help processors make an informed choice.

Each material is optimized for performance with different types of plastic sheet, temperature use, machining conditions, surface finish, durability and even pricing.  While every HYTAC® product is suitable for a wide variety of applications, making the “best” choice reduces machining costs, improves material distribution, enhances clarity, reduces plastic residue sticking to the plug and maximizes plug life.

Though some materials may initially cost more as a percentage of the overall tool price, it is important to understand the total cost of ownership. In other words, the savings generated over the life of a particular project should all be taken into consideration, from time in the machining center to set-up time, from production of initial parts to perfection of consistent parts, not to mention the cost of replacing any damaged plugs due to a production mishap.

Please refer to our CMT Material Selector Guide for more information. Of course, you can always contact us at any time and we’ll be happy to discuss your application with you.