AL-KO Plast GmbH

FAQ Technology

Ultramodern vacuum thermoforming machines are employed for deep drawing at AL-KO Plast GmbH. Sheet thermoforming machines are used for material thicknesses over 2 mm. Ultramodern automatic pressure forming machines are used for thicknesses under 2 mm.


Deep drawing is a method employed in plastics processing. During thermoforming, a fundamental distinction is made between negative and positive forming. During negative forming, the heated intermediate is sucked or pressed into the concave mould cavity, during positive forming it is sucked onto a convex model (positive mould core). The side in contact with the mould is later smoother and more dimensionally accurate.


Compared with traditional injection moulding, deep drawing is by far the more cost-effective method for small and medium quantities as the tool costs involved are considerably lower than those for injection moulding. Furthermore, specimens, prototypes or even small series can be developed very quickly, if necessary.


That depends on the plastics employed and on the size of the vacuum thermoforming machines available. Plastics with a starting thickness from 0.3 mm to 14 mm are processed at AL- KO Plast GmbH. The mouldings can have dimensions up to 2950 x 1450 mm (L x W).


The largest forming area at AL-KO Plast GmbH measures 3.000 x 1.500 mm, the maximum drawing height/drawing depth is 900 mm, both positive and negative.


Through the use of CNC-milled and cooled aluminium moulds together with high-quality plastics, mouldings can be produced that match the quality of injection mouldings.


All classic thermoplastic polymers can be deep drawn. These can be on the one hand the typical polyolefins such as PE, PP, styrene, copolymerisates such as polystyrene, ABS, SAN, ASA, but also technical thermoplastics such as PC, PMMA, PET, PVDF, etc.


Depending on the batch size and quantity, mouldings can be precision milled on ultramodern CNC machining centres.
This can be followed by further processes such as:

  • Bonding
  • Joining
  • Welding
  • Drilling
  • Metallising
  • Printing

It is fundamentally possible, for example, to subsequently paint products of PS or ABS, and the products can be printed using a variety of printing methods (screen printing, pad printing, etc.).


As one of the thermoformers, AL-KO Plast GmbH offers the complete development, design, prototyping and series production from a single source. The moulds are produced in our ultramodern mouldmaking shop. Furthermore we have the possibility to examine and test products under special conditions (fatigue loading, exposure to heat or cold, UV radiation, etc.).


It is fundamentally possible to process all transparent or translucent plastics. These include materials such as:

  • PVC
  • Styrolux®
  • PMMA
  • PET
  • Polycarbonate


AL-KO Plast GmbH has its own specimen production shop in which prototypes are produced for customers. Furthermore, we cooperate with designers and can offer our customers suggestions for the design and appearance of their products and implement these very quickly.


AL-KO Plast GmbH has been certified to ISO 9001 since 1994. We are now working to achieve certification to ISO 2000. Quality starts with us at all administrative and production levels of the company with the acceptance of the order. Through ongoing training and further qualification measures, we ensure a high standard of training of our employees who are directly involved in the implementation of agreed quality goals and standards.


DIN ISO 9001 defines a quality management system covering all departments and levels of a company.
It applies not only to the classic departments of production and administration, but also to the developments. The AL-KO Plast GmbH conducts permanent internal and external audits in order to demonstrate that the demands of DIN ISO 9001 are satisfied.