TIM INFINITY / PROJECT
Modular HIPS Shelf Stopper
A modular shelf stopper — a plastic retail POS display element for presenting products on a shelf — was developed for a point-of-sale promotional application.
The requirement was to develop an element made from several separate thermoformed parts that fit together and can be connected into a larger unit where required.
TIM Infinity carried out product development and design, tooling design and manufacture, production of functional prototypes, thermoforming of 1.5 mm white HIPS and final trimming of the parts.
01
Project requirement
The starting requirement was to create a plastic promotional element for displaying products on a retail shelf.
In addition to the appearance and dimensions defined by the intended application, a key part of the requirement was modular connection of the individual elements. Each part needed to work independently, while also fitting accurately with an adjacent part to form a longer connected display surface.
The geometry of the thermoformed part, the connector shape and the final trimming method therefore had to be coordinated during development.
02
Development of the modular system
The geometry of the individual element and the interconnection system were developed from the project requirements.
The joints were designed so adjacent parts fit into one another and form a continuous assembly. The same basic element can therefore be used for different display lengths depending on the available shelf space.
Particular attention was paid to the transitions between parts and to the formed front edge so that connected elements function and appear as a single consistent unit.
Custom plastic product manufacturing03
Tooling design and manufacture
Once the product geometry had been defined, the tools required for thermoforming were designed.
The tooling geometry was adapted to the HIPS part shape, radii, raised front edge and the zones that needed to be trimmed accurately after forming to create the modular connections.
The completed tools were used to produce trial parts and verify the complete concept.
Thermoforming tooling design and manufacture04
Thermoforming 1.5 mm white HIPS
The elements were manufactured by thermoforming 1.5 mm white HIPS.
Thermoforming produced the basic three-dimensional geometry of the part, including the flat product-display surface and the formed front edge.
After forming, each component was additionally trimmed to the defined contour to create the joints required for modular connection.
Thermoforming & Vacuum Forming HIPS and other thermoforming materials05
Functional prototypes and fit verification
Functional prototypes were produced as part of the project and used to check the geometry and connection method.
Individual parts were assembled in several configurations to verify that the joints located correctly and that the connected elements formed a stable and visually consistent assembly.
The project was completed at functional-prototype stage; a production or pilot run was not part of the approved project scope.
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TIM Infinity can cover product development, tooling manufacture, thermoforming and finishing of plastic parts.
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