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Design


 

What we do at the factory.

Thermal forming is, at its core, the process of taking a sheet of plastic material, heating it up until its pliable, and forming it to a three-dimensional shape. Here’s how the Bray thermal forming process works.

 

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Design


 

What we do at the factory.

Thermal forming is, at its core, the process of taking a sheet of plastic material, heating it up until its pliable, and forming it to a three-dimensional shape. Here’s how the Bray thermal forming process works.

 

 

Step 1 - Design

Every thermal forming windshield project starts out with a design. Usually, thermal formed plastic is used as a part of a larger production orders. Often though certainly not always, it’s an outer temporary protective covering for production and delivery of a vehicle. Whatever it’s being used for, most thermal formed products start out as a CAD model or drawing. Often, when our customers come to us with a windshield, our engineers work with the customer to refine the 3D kit into a size that will work well with the specific requirements that are needed. 

 
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Material


Thermal forming since 1999.

Every material has unique physical properties and benefits

Material


Thermal forming since 1999.

Every material has unique physical properties and benefits

 

Step 2 - Material options

After the final designs are ready, we work with our customers to select the right material for their project. There are quite a few options that can be selected for either temporary or retail reasons, including Bray new no scratch multi-layer materials. Every material has unique physical properties and benefits, and thermal forming also allows for a finished product that can greatly enhance the ease of installation.

 
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Tooling


New 72 hour tooling setup ability.

The creation of the machine/mold that the material will be heated to, commonly called tooling.

Tooling


New 72 hour tooling setup ability.

The creation of the machine/mold that the material will be heated to, commonly called tooling.

 

Step 3 - Tooling

The next step in the thermal forming process is the creation of the machine/mold that the material will be heated to, commonly called tooling. Our thermal forming process uses factory windshield molds for its thermal forming machine. Depending on the size and complexity of the materials being used in the project, it’s often possible to mold the PET in one piece, reducing clients installation costs, material costs and production times. Our large scale thermal forming capabilities make this a compelling option for many large volume and in line factory account.

 
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Cutting


In-house digitizing technology. 

Bray uses cutting equipment that can quickly cut complex and precise shapes.

Cutting


In-house digitizing technology. 

Bray uses cutting equipment that can quickly cut complex and precise shapes.

 

Step 4 - Cutting

Once a piece of windshield is digitized, Bray uses cutting equipment that can quickly cut complex and precise shapes, resulting in faster production times and more accurate and flexible cuts. At Bray, our equipment also performs secondary operations such as cutouts, through holes and other features that require the removal of material.

 
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Thermal


Master in-house cutting equipment.

Faster production times and more accurate and flexible cuts.

Thermal


Master in-house cutting equipment.

Faster production times and more accurate and flexible cuts.

 

Step 5 - Thermal forming

Once the materials are selected, the tooling has been created, the material has been cut, the next step is to actually form the PET to the mold. This is done by first heating the PET sheet to a pliable temperature, then shaping it to windshield with proprietary equipment and process. Once the material has been formed to the mold, it’s cooled and removed from the mold, retaining its final shape. Since the final project cools against the mold surface under ambient temperatures, final product has zero  

 
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Packing


 

Proprietary packaging options.

We offer many proprietary packaging option that prevent damage to the PET material.

 

Packing


 

Proprietary packaging options.

We offer many proprietary packaging option that prevent damage to the PET material.

 

 

 

After a custom material has been cut and thermal formed, that’s still not always the end of the story. At Bray, we offer many proprietary packaging option that prevent damage to the PET material. Combined with our proven supply chain management, these services let us work as a single-source partner for many of our customers, so that when they receive the completed part from Bray, it’s fully ready to integrate with the rest of their manufacturing process.