Frequently Asked Questions

Thermoforming is a generic term for the process of producing plastic parts from a flat sheet of plastic under temperature and pressure. Thermoforming offers close tolerances, tight specifications, and sharp detail. When combined with advanced finishing techniques, high-technology thermoforming results in products comparable to those formed by injection molding. Thermoformed parts have replaced many parts previously manufactured from wood, paper, glass, fiberglass and metal.

Inexpensive Tooling
Prototypes and permanent molds are substantially less expensive than injection molds.

Better Physical Properties In Finished Part
In thermoforming, the heated sheet is virtually stress free compared to other polymer manufacturing methods. When properly formed, the sheet is stretched at the forming temperature before it is cooled against the mold. This sets up a very minimum of internal stress in the finished part.

Ability To Take Advantage Of Multiple Layer Sheet Material
Thermoforming technology makes full use of multiple layer sheet material. Decorative and/or weather resistant caps can be applied to the extruded sheet prior to forming.

This combines a strong impact resistant substrate with a functional and highly cosmetic surface.

Pressure Forming Fine Detail
A thermoforming process similar to Vacuum Forming, with a pressure assist forcing the material to conform to every detail of the mold.

Ability To Form Very Large Parts
Relative to other processing methods, part sizes up to 5 ft x 8 ft (1.524 x 2.44 m) can be thermoformed easily and economically.

Sharp, crisp detail with close tolerances can be achieved. Undercuts, formed-in texture, formed-in logos, formed-in hardware, and custom colors are just a few of the many features that can be accomplished with thermoforming.
It is a thermoforming process similar to Vacuum Forming, with a high pressure air assist. Pressure Forming provides greater definition of part, comparable to injection molded parts with much lower tooling costs.
We will be most cost efficient in part runs between 100 and 5,000. We will also be more competitive in higher volumes if the part size is larger.
Parts can be produced in ABS, Polyethylene, Styrene, Acrylic, PETG, TPO, Polycarbonate, PVC and other engineered plastics.
Drape forming, a simple method where a heated plastic sheet is manually draped onto a mold.

Secondary assembly, such as riveting, fastening and adhesive bonding.

Plastic fabrication: With our high tech routers and our experience in gluing and bonding, we can make high quality finished parts.
Much less time is required than with injection molded products. Production can often start within 6 weeks after design approval.

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