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Introduction to Thermoforming

Course Details

Instructor: Christopher Gagliano 

Hours of Instructions: 1 1/2 Day

Course Prerequisite:  None

Date: November 3-4, 2026

Price: $975


This 1.5 day workshop will cover the essential elements of thermoforming from materials to finished product as it applies to both thin-gauge (roll-fed and in-line) and heavy-gauge (cut-sheet) thermoforming applications. Instruction includes live sheet extrusion and material testing demonstrations. This entry level course is designed for machine operators, set-up technicians, supervisors, quality, office and sales staff to improve their understanding of materials, design fundamentals, and the overall process.

 

What You'll Learn:

  • Basic Overview of Thermoplastic Materials
  • Thin and Heavy Gauge Equipment Options
  • Sheet Extrusion
  • Polymer Testing
  • Importance of Heating the Sheet and Cooling the Part
  • Product and Mold Design Basics
  • Plug Assist Design and Materials
  • Trimming Methods
  • Basic Troubleshooting of the Process and Equipment

Lecture Topics:

  • History of Thermoforming
  • Safety
  • Thermoforming Equipment
  • Thermoplastic Materials
  • Processing Techniques
  • Part & Mold Design
  • Plug Assist
  • Trimming Methods
  • Troubleshooting the Process & Equipment

Outcomes - Upon successful completion of the course, participants will understand:

  • Basics of the thermoforming process
  • Thermoforming lingo
  • Safe operation of the forming and secondary equipment
  • Various processing techniques available
  • Importance of sheet quality
  • Importance of heating and cooling principles and their effect on the final product
  • How a plug assist works to improve material distribution
  • Troubleshooting basics


To register, please download the registration form.


Location

Polymers Center

8900 Research Drive

Charlotte, NC 28262

(704) 602-4100


Dress Code

Business casual

Polo or button down shirt

Long pants

Closed toe shoes, no heels


Lab Etiquette

No drinks, food or gum

No tobacco or vaping devices

Safety glasses must be worn


Christopher Gagliano


Christopher Gagliano retired in August 2025 after 13 years at Pennsylvania College of Technology, where he held the role of Director of the Plastics Innovation & Resource Center, supporting industry needs for workforce training and Research & Development projects. Since his retirement and through his company Phoenix Plastics Consulting, he provides consulting and customized training services to the thermoforming industry.

For 25 years prior to Penn College, he worked in the heavy gauge thermoforming industry in a variety of roles including manufacturing, quality, tooling, engineering, and technical sales. He is a member of the SPE Thermoforming Division, Association of Rotational Molders (ARM) and Manufacturer's Agents National Association (MANA).