Industrial Heating Fundamentals for Thermoforming Plastic Pipes

Because of its strength, moisture resistance, electrical insulation, and low cost, plastic piping remains a versatile material across a wide range of industrial applications. The thermoforming process of plastic piping involves heating and shaping extruded pipes or hoses using controlled hot air to achieve your desired geometries. Regardless of the specific forming method, bending rigid plastic always requires carefully applied heat and force. Check out a real success story in the next section.

Case Study 

One client in this industry approached us seeking a more efficient and consistent solution for their pipe bending and forming process. Their setup involved applying heat at key bend points, bending the pipe into shape using a jig, and allowing it to cool to permanently retain its contour. Each workstation was equipped with a large heater below the bench that delivered hot air to the required bend points. However, this system proved inefficient causing significantly variable air temperature from one bend point to the next. With temperature inconsistency comes discoloration (too hot) and possible pipe failures (too cold).

 To solve this, TUTCO SureHeat replaced the large, cumbersome heater located below the workstation with a series of small individual Hot Air Tools, located at each bend point in the process. These precise electric air heaters feature built-in thermocouples for accurate temperature monitoring and control. The 304 stainless steel body is designed for durability and includes slots for flared accessories, supporting pressures up to 60 psi (4 bar) and temperatures up to 1400°F (760°C). Compact, lightweight, and highly efficient, the Hot Air Tool is ideal for single-phase OEM applications that demand precise, high-temperature performance. 

By integrating TUTCO SureHeat Hot Air Tools, the customer gained complete control over the temperature at each bend point. Gone were the days of discolored and cracked joints that required rework (and potential scrap). The client reported consistent heating, faster production times, and significantly reduced energy waste. 

Final Thoughts 

We collaborate with OEMs and manufacturers to design and integrate custom heating solutions that enhance precision, safety, and throughput in plastic forming, welding, and device manufacturing applications. From small-scale forming tools to high-volume production systems, our thermal expertise helps customers achieve repeatable quality and energy-efficient performance for years to come.