Lightweight. Efficient. Multifunctional. The demand for components that require hybrid manufacturing technologies is steadily increasing. One of the most effective approaches to this request is to integrate thermoforming with a complementary process (depending on the application), such as polyurethane (PUR) foaming for insulation or Interwet-LFI for structural reinforcement. Each combination serves a different functional goal, but both leverage thermoforming as the foundation for creating advanced, integrated structures with enhanced performance. Cannon is the only supplier in the world capable of providing the entire production plant for blending these technologies.
Learn how thermoforming combined with PUR insulation or Interwet-LFI reinforcement creates lightweight, high-performance components with enhanced thermal efficiency, structural strength, and manufacturing efficiency. Discover the benefits of integrated production processes and Cannon’s unique turnkey solutions for advanced hybrid manufacturing.
June 18, 2026
The hunt for high-performance lightweight structures
The role of thermoforming
Thermoforming enables complex geometries that maintain a high surface quality, making it ideal as a visible outer layer or functional skin in multi-material systems. This versatile manufacturing process takes a thermoplastic sheet (typically ABS or PP), heats it until soft, and shapes it over a mold. The final part is obtained by trimming away the excess plastic.
In hybrid processes, the thermoformed component typically acts as the external layer, combining aesthetics, geometry, protection and, occasionally, functional features such as ribs or channels.
Thermoforming meets the PUR insulation process
Integrating the thermoforming process with a PUR insulation process is the more established of the two applications. Here, a thermoformed shell is paired with another layer — such as a metal sheet or plastic backing (commonly in refrigerators) — and placed into a mold. PUR is then injected into the cavity between the layers where it expands into a closed-cell foam, filling the space and adhering to the surrounding thermoformed material. Once cured, the foam forms a rigid low-density core that provides thermal insulation and contributes to the component’s structural integrity.
This approach is widely used in domestic and commercial refrigerators, insulated vans and panels, and building applications, where thermal efficiency is critical. The resulting structures combine low thermal conductivity with lightweight construction and integrated bonding, reducing the need for additional fasteners or adhesives.
Twin sheet thermoforming is an ideal technology for producing hollow parts with structural mechanical properties and the natural candidate for integrating PUR insulation. In this configuration, both manufacturing steps can be performed within the same machine without moving the part. The twin sheet mold itself serves as the foaming tool, eliminating the need for any additional tooling.
Combining thermoforming with Interwet-LFI
This application targets a component’s structural performance, providing a composite backing that offers a high strength-to-weight ratio while maintaining an outward aesthetic and eliminating the need for additional reinforcements.
The Interwet-LFI process involves combining long glass fibers with a liquid resin system, generally PUR. This mixture is sprayed (not injected) onto the reverse side of the thermoformed part. Then it is quickly moved into a press where the material is compressed and consolidated to ensure a strong adhesion between the new composite backing and the thermoformed skin. Once cured, the result is a rigid, glass fiber-reinforced structure.
To take this combination of technology one step further, our “POSSIBLE” project demonstrated that recycled GFRP composites can be used efficiently in this process. Find out more about the patented mixing head, which allows the glass fibers to be sized and shredded directly inside the mixing chamber immediately before spraying.
Where are these approaches applicable?
The combined use of these technologies spans multiple sectors. In refrigeration and construction, thermoforming with PUR insulation is the standard for insulated enclosures, cold storage systems, and panels.
In automotive and transportation, thermoforming with Interwet-LFI is widely used for semi-structural and structural interior components. In the agricultural sector, this combination is used to create external body panels (hood, roof, rear, side) for large vehicles, including tractors, busses, and trains, which maintain a glossy aesthetic appearance. Where thermal and acoustic insulation are required, recreational vehicles can also benefit from this combination.
Both methods contribute to manufacturing efficiency. By combining multiple steps — forming, bonding, and either insulating or reinforcing — into a single workflow, manufacturers can reduce assembly time, minimize part counts, and improve overall production efficiency. Whether the goal is thermal efficiency or structural strength, these combinations offer manufacturers a flexible and efficient way to meet modern engineering demands.
As material technologies and processing techniques continue to evolve, such hybrid approaches are likely to play an increasingly important role in the future of lightweight design and manufacturing. Integrating multiple technological steps into a single production cell may result in slightly longer cycle times and a higher per-part machine cost. Nevertheless, these trade-offs are balanced by a substantial reduction in tooling investment, along with a lower risk of part damage thanks to minimized handling between operations.
The integration of thermoforming and reactive polymer processes marks a shift toward fully engineered components, where geometry, insulation, and reinforcement are designed as one. As sustainability and lightweighting demands grow, this integrated approach is becoming the new industry standard — and Cannon continues to drive it forward through ongoing investment in technology, materials, and process expertise.
Choose Cannon over the competition
Integrating multiple processes into a single production line becomes a key competitive advantage for offering lighter, more efficient, and more functional components. Cannon is uniquely positioned as the only supplier who can create complete turnkey solutions for both thermoforming-PUR insulation and thermoforming-Interwet-LFI processes, providing customers with fully integrated technology and a single point of contact throughout the entire process. Supported by advanced laboratories and experienced specialists, we can assist with trials and feasibility studies to help customers confidently adopt new technologies. Whatever the client’s goal — thermal performance, structural reinforcement, or both — our engineering team is ready to guide you to the best solution for your application.
Are you looking for a tailored solution?
Contact us today to discuss your specific needs and find out how our custom solutions can enhance your production process. Don’t wait — let’s create excellence together!
