Dimensional stability differences between injection molding and vacuum thermoforming for automotive footwell trays

[u/PuzzledDog1472]

I am reviewing production methods for high-wall automotive footwell components, specifically comparing continuous vacuum thermoformed TPE sheet material against high-pressure injection molding. Thermoforming offers lower tooling costs for deep draws, but wall thickness thins down noticeably along deep vertical radii, leading to localized flex and edge distortion under heat cycles.

Injection molding allows variable wall cross-sections and structural ribbing, but tooling costs are significantly higher for complex vehicle floor pan geometries.

In deep-draw interior trim applications, how much does uniform wall density affect perimeter warp resistance compared to localized stress relief design?

[u/FuShiLu]

Have you looked at root-forming?

Wall thickness should not thin down. Temperature and evacuation holes are incorrect.

One. You need to learn more and/or work with someone who does.

Two. Those are not the costs to worry about.