The performance of thermoplastic materials changes significantly at low temperatures, and for vacuum formed components intended for use in cold climates or outdoor winter environments, material selection is particularly critical. At Jabro Games, we supply components for applications across a wide range of environmental conditions and want to share what we know about how vacuum forming materials behave when the temperature drops.
Impact Performance at Low Temperature
Most thermoplastics become less tough at low temperatures — the material’s ability to absorb impact energy without fracturing reduces as the temperature falls. This effect is particularly pronounced in materials such as standard polystyrene, which can become brittle at temperatures below 0°C. ABS and impact-modified grades of other materials maintain better low-temperature impact performance and are preferable for applications where the formed component may be subjected to impact in cold conditions — outdoor enclosures, equipment panels, and transport packaging for goods stored or transported at low temperatures.
Polycarbonate: The Cold-Temperature Champion
Polycarbonate is one of the few thermoplastics that maintains excellent impact resistance at very low temperatures — down to -40°C and below in standard grades. This makes it the material of choice for applications requiring high impact resistance in extreme cold environments, including outdoor lighting components, safety glazing, and equipment used in cold storage or refrigerated transport. Its optical clarity also makes it suitable for visibility applications in cold environments.
Dimensional Stability
Thermal expansion and contraction — the dimensional change that materials undergo as temperature changes — affects the fit of vacuum formed components in assemblies and enclosures. Materials with lower coefficients of thermal expansion, such as polycarbonate and certain grades of ABS, maintain more consistent dimensions across temperature ranges and are preferable where tight fit is required across a range of operating temperatures.
Sealing and Gasket Considerations
Vacuum formed enclosures used in cold or outdoor environments frequently incorporate seals or gaskets to exclude moisture and contaminants. The seal material must remain flexible at the lowest expected operating temperature — rubber and silicone gaskets that are pliable at room temperature can harden significantly in severe cold, compromising the seal integrity. Specifying seal materials with appropriate low-temperature flexibility is as important as selecting the correct enclosure material.
To discuss material selection for cold-climate vacuum forming applications, contact Jabro Games at jabrogames.com.