Thermoforming & Vacuum forming Services

Thermoforming and vacuum forming are manufacturing processes used to produce plastic parts by heating a thermoplastic sheet until it becomes pliable, then forming it over a mold using vacuum pressure, mechanical force, or a combination of both. Once formed, the part is cooled and trimmed into its final shape. These processes are well-suited for producing lightweight and cost-effective components with faster tooling.

Capabilities

  • Custom sheet thermoforming for unique part geometries, deep draws, large-format components, and application-specific designs requiring tailored tooling and consistent part repeatability
  • Vacuum forming for lightweight, cost-effective, and detailed components with efficient tooling and fast turnaround for prototype, bridge, and production programs
  • Pressure forming for enhanced detail, tighter tolerances, and superior surface finish, enabling more complex geometries and cosmetic-grade part quality compared to standard vacuum forming
  • Specialize in forming thermoplastic sheets ranging from 0.010” to 0.060” in thickness, supporting both thin-gauge lightweight packaging components and durable formed parts requiring structural integrity and consistent dimensional performance.
  • High-speed inline forming using Lyle thermoforming systems with a 30” x 40” platen, ideal for high-volume production runs with integrated in-line die cutting (up to 65 tons of cutting pressure) and automated up-stacking for efficient output
  • Inline forming and off-line die cutting capabilities, providing flexibility in production flow, part complexity, and finishing requirements compared to traditional station forming systems
  • Full program support including part design assistance, DFM (Design for Manufacturability), tooling design, prototyping, production scaling, and secondary finishing operations
  • Secondary services include precision trimming and CNC cutting, die cutting, drilling and machining, heat staking and heat insertion, assembly and sub-assembly integration, bonding and fastening, edge finishing and cosmetic cleanup, labeling and branding, inspection and quality control, and custom protective or retail packaging for finished parts
  • Quality inspection including dimensional verification, visual inspection, and functional validation to ensure consistency and performance requirements
  • On-time delivery with JIT (Kanban) programs

Cost-Effective Production

Lower tooling costs compared to other molding methods for large parts.

Lightweight Component Design

Ideal for producing durable parts with reduced material weight.

Large Part Capabilities

Efficiently form oversized components with consistent quality.

Material Versatility

Supports a wide range of thermoplastic materials for diverse applications.

Key Materials for Thermoforming & Vacuum forming

  • Acrylonitrile Butadiene Styrene (ABS): A strong, impact-resistant material commonly used for industrial housings, automotive interior panels, machine covers, and durable formed components requiring toughness and dimensional stability.
  • High Impact Polystyrene (HIPS): A cost-effective, easy-to-form material ideal for prototypes, packaging, trays, and light-duty enclosures where good formability and low cost are key priorities.
  • Polycarbonate (PC): A high-strength, transparent thermoplastic offering excellent impact resistance and heat performance, used for protective guards, medical housings, and clear structural components.
  • Polyethylene Terephthalate Glycol (PETG): A clear, tough, and highly formable material commonly used in medical packaging, retail displays, protective covers, and applications requiring clarity and impact resistance.
  • Polymethyl Methacrylate (PMMA, Acrylic): A rigid, optically clear material used for display components, signage, cosmetic housings, and applications requiring high optical clarity and surface finish quality.
  • Polypropylene (PP): A lightweight, chemically resistant thermoplastic commonly used for industrial trays, packaging components, automotive interior parts, medical packaging, and applications requiring fatigue resistance and good formability.
  • High-Density Polyethylene (HDPE): A durable, chemical-resistant material used for industrial trays, containers, liners, and protective components exposed to harsh environments or chemicals.
  • Low-Density Polyethylene (LDPE): A flexible, lightweight material used for cushioning components, liners, and applications requiring impact absorption and flexibility.

Common Thermoforming & Vacuum forming Applications

  • Medical & Healthcare: Device housings, instrument trays, sterilization trays, packaging inserts, protective covers, and diagnostic equipment enclosures requiring cleanability, durability, and consistent dimensional performance.
  • Automotive & Transportation: Interior trim panels, door liners, trunk liners, HVAC housings, protective shields, and lightweight structural components used for functional and aesthetic applications.
  • Aerospace & Defense: Interior cabin panels, lightweight covers, storage compartments, protective enclosures, and non-structural components designed for weight reduction and performance reliability.
  • Industrial Equipment: Machine guards, equipment housings, protective covers, work trays, and durable enclosures designed for harsh operating environments and repeated use.
  • Retail & Point-of-Purchase (POP): Display trays, product displays, signage backers, retail enclosures, and merchandising components requiring visual appeal and cost-effective production.
  • Packaging & Material Handling: Custom trays, clamshell packaging, protective inserts, shipping trays, and formed packaging solutions for product protection and organization.
  • Consumer Products: Appliance panels, storage components, protective housings, and decorative enclosures used in household and commercial consumer goods.
  • Electronics & Electrical: Equipment housings, protective covers, internal mounting panels, and insulating components for electronic devices and systems.

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