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Thermoforming
Heavy-gauge and thin-gauge thermoforming for industrial parts, enclosures, trays, radomes, and custom assemblies — from a single prototype to long-run production.
What is thermoforming?
Thermoforming is a plastic-forming process where a sheet of thermoplastic is heated to a pliable forming temperature, draped or pressed over a tool, and cooled to take the shape of the tool. The result is a finished part that's typically larger, lighter, and faster to produce than equivalent injection-molded or fabricated parts — and at a fraction of the tooling cost.
We run both heavy-gauge thermoforming (sheets thicker than 0.060" — for enclosures, vehicle panels, equipment housings, trays) and thin-gauge (under 0.060" — for trays, packaging, lids, and disposables). Tooling can be aluminum, composite, or wood depending on the volume and tolerance you need.
For projects where the right answer is actually injection molding, we'll tell you that too.
Our process
- 01Tooling & setupAluminum or composite tooling sized to your part envelope. Single- or multi-cavity depending on volume.
- 02Sheet heatingPlastic sheet is uniformly heated until pliable. Temperature profiles tuned per resin and gauge.
- 03FormingVacuum, pressure, or twin-sheet forming pulls the sheet to the tool. Drape, plug-assist, or matched-mold methods as required.
- 04Trimming & finishingCNC routing of the cooled part, edge finishing, hole locations, and any secondary operations.
- 05Inspection & shipDimensional check against drawing, visual QC, packaging, and shipment.
Materials we form
We work with a wide range of commodity and engineering thermoplastics. Don't see your material? Ask — we likely run it.
Got a thermoforming project?
Send us a drawing or sketch. We'll respond with a quote, lead time, and any DFM feedback that can save you money.