More answers than questions.

Vacuum forming can be a complicated process, and while we’re always available via phone or email to answer your questions, we’ve complied this list of commonly asked questions to help you understand the entire process better.

What is the process known as “thermoforming” or “vacuum forming”?
Vacuum forming, known generically as Thermoforming is the process in which a sheet of plastic is held in a frame, heated to a prescribed temperature, and pulled down into or over a mold. Vacuum is applied to keep the plastic in place and held tight to the tool or mold.

What materials can Electro-Generals work with?
EGP can form virtually any thermoplastic, including HDPE (High Density Polyethylene), LDPE (Low Density Polyethylene), HMWP, ABS (Acrylonitrile-Butadiene Styrene, fire retardant included), HIPS (High Impact Polystyrene), PE, PETG, PVC, Acrylic and Polycarbonate. If necessary, we can advise you as to the appropriate material based upon your application. {See those added above}

What’s the largest substrate part size EGP can work with?
EGP is capable of forming materials from .030 up to .500 inches with sheet sizes to 72″ x 126″ (part size 68″ x 120″).

What’s the difference between REN, Machined or Cast Aluminum tooling as it pertains to my job?
Ren board is used for low production runs of less than 50 pcs, great for prototypes or preproduction. Machined Aluminum tooling is for shallow parts under 4” in depth and can be mounted to a water plate for temperature control of the tooling and part.

Cast Aluminum tooling is for parts deeper or taller than 4” in and can have water lines cast into the mold for temperature control of the tooling and part.

What work does EGP do for the tire industry?
EGP also manufactures a full line of Bead and Apex Separators and Green tire seats for the tire manufacturing industry. Low profile and Raised style bead and apex separators and Flat or Parabolic tire seats are available. EGP is an OE supplier to Spadone-Hypex. Contact us for details and a complete list of products.

Why does EGP have two locations so close together?
Our main location in Grove City, Ohio right outside Columbus and our second location Cookeville, Tennessee. The advantage of these two locations is their proximity to one another. Should one plant need supplies or a piece of equipment, the other plant is less than a day a way to supply it which means your job is never delayed.

What equipment does EGP have?
Our 37,000 square foot Grove City facility includes (6) rotary and (3) single stations for forming and (6) presses for die cutting. We also employ a 5-axis Thermwood router & Quintax for part trimming and a 3-axis CNC router for cutting parts and flat stock.

The 20,000 square foot Mid-Tenn division includes (2) rotary and (1) single station as well as (1) press and a 5-axis Thermwood CNC for finishing. Radial saws, band saws and routing stations round out the list of equipment employed by EGP.

What industries does EGP work with?
Everything from automotive, heavy truck, food, electrical appliances to signage, consumer goods, and displays.

Can EGP design my project as well as manufacture it?
EGP works with several Industrial Design firms so if you don’t have a design for a specific application, EGP can help you achieve your goal, from the simple to the complex. EGP is capable from designing everything from simple consumer parts like in-store displays to entire mass transit bus interiors.

How fast can EGP go from full data drawings to prototype parts?
EGP can go from full data drawings to prototype parts in as little as 2-3 weeks.

How fast can EGP go to full production parts?
EGP can produce full production parts in 5-7 weeks.