Form-Cut-Stack Thermoforming Tooling

BMG manufactures form-cut-stack tooling for designed for high-speed, thin-gauge thermoforming applications. In the form-cut-stack process, plastic sheet is heated and formed, the indexed web advances to a dedicated cutting station, and finished parts are separated and transferred to an upstacker, downstacker, or robotic stacking system. The tooling is side loaded into the forming and cutting stations to support accessible tool changes and efficient production setup. BMG develops the form tool, trim tool, stripper and support components, and stacking interface as a coordinated system, evaluating product geometry, material, equipment platform, sheet index, cutting force, part release, and stack presentation to maintain accurate registration and consistent performance from forming through finished-part handling.

BMG configures form-cut-stack trim tooling with knife technology suited to the material, sheet gauge, product geometry, edge-quality requirements, and production rate. Options may include steel-rule knives, forged knives, machined cut knives, and matched punch-and-die components, along with pre-punch, scoring, scrap-cutting, and heated-trim features when required. The correct knife profile, cutting clearance, support, alignment, and force help produce clean cut edges, limit angel hair and hanging scrap, protect formed parts, and support reliable part separation at production speed.

BMG manufactures form-cut-stack tooling in a temperature-controlled facility using precision machining capabilities that include wire EDM, jig grinding, jig boring, and ID/OD grinding. Tool materials, knife styles, coatings, heat treatment, and replaceable wear components are selected around cutting performance, maintenance requirements, and expected tool life, while coordinate measuring machine (CMM) inspection verifies critical dimensions, alignment, and interchangeability against approved specifications. As a single-source manufacturing partner, BMG can align tooling with compatible thermoforming equipment, servo-controlled forming and cutting stations, plug-assist systems, material handling, scrap systems, and stacking automation, with support for reverse engineering, modifications, repairs, rebuilds, replacement components, installation, startup, and ongoing service.