Thermoforming / Vacuum Formed Plastic Parts Gallery
Thermoformed Plastic Carrying Case
Material: High Density Polyethylene (HDPE)
Product Description: Twin sheet thermoforming was utilized to make this plastic protective carrying case for laser leveling equipment.
Secondary Operations: Following the initial thermoform, secondary operations included perimeter routing, drilling, gluing, and complete in-house assembly.
Dimensions: 42" x 10" x 12"
Quantities: This custom plastic thermoformed case was produced in production quantities approximately 10,000/year.
Material: High Density Polyethylene (HDPE)
Product Description: Twin sheet thermoforming was utilized to make this plastic protective carrying case for laser leveling equipment.
Secondary Operations: Following the initial thermoform, secondary operations included perimeter routing, drilling, gluing, and complete in-house assembly.
Dimensions: 42" x 10" x 12"
Quantities: This custom plastic thermoformed case was produced in production quantities approximately 10,000/year.
Pressure Formed Controller Panel for Medical Analyzing Equipment
Material: FR Rated ABS
Product Description: Pressure forming is used to create this aesthetically pleasing plastic control panel for a medical equipment manufacturer.
Secondary Operations: Assembly of rib structure, CNC trimming and machining and applying threaded inserts. Front surface of this thermoformed panel is painted and pad printed.
Dimensions: 12" x 9" x 2"
Production Notes: Pressure forming could provide better product detail than any other thermoforming method resulting in a product that looks very similar to an injection molded product, but with a much lower tooling cost.
Material: FR Rated ABS
Product Description: Pressure forming is used to create this aesthetically pleasing plastic control panel for a medical equipment manufacturer.
Secondary Operations: Assembly of rib structure, CNC trimming and machining and applying threaded inserts. Front surface of this thermoformed panel is painted and pad printed.
Dimensions: 12" x 9" x 2"
Production Notes: Pressure forming could provide better product detail than any other thermoforming method resulting in a product that looks very similar to an injection molded product, but with a much lower tooling cost.
Twin Sheet Formed Sewer System Water Chlorinator
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing is utilized once the thermoforming is completed.
Dimensions: 20" x 34" x 9"
Quantities: 1,000 per year
Production Notes: Twin sheet thermoforming created a hollow, finished product that appears similar to a rotationally molded or blow molded part. Thermoforming was the chosen manufacturing method due to having a much lower tooling cost than blow molding and a lower piece-price than rotational molding.
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing is utilized once the thermoforming is completed.
Dimensions: 20" x 34" x 9"
Quantities: 1,000 per year
Production Notes: Twin sheet thermoforming created a hollow, finished product that appears similar to a rotationally molded or blow molded part. Thermoforming was the chosen manufacturing method due to having a much lower tooling cost than blow molding and a lower piece-price than rotational molding.
Vacuum Formed Drainage Tile Coupler
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing is utilized once the thermoforming is completed.
Dimensions: 20" x 34" x 9"
Quantities: 1,000 per year
Production Notes: Twin sheet thermoforming created a hollow, finished product that appears similar to a rotationally molded or blow molded part. Thermoforming was the chosen manufacturing method due to having a much lower tooling cost than blow molding and a lower piece-price than rotational molding.
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing is utilized once the thermoforming is completed.
Dimensions: 20" x 34" x 9"
Quantities: 1,000 per year
Production Notes: Twin sheet thermoforming created a hollow, finished product that appears similar to a rotationally molded or blow molded part. Thermoforming was the chosen manufacturing method due to having a much lower tooling cost than blow molding and a lower piece-price than rotational molding.
Vacuum Formed Case
Product Description: Rugged light-weight thermoformed protective carrying case for use in military aviation.
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing, drilling, assembly/attachment of handles, hinges, and foam insert are completed after thermoforming is completed.
Dimensions: 28" x 18" x 8
Quantities: 500 per year
Production Notes: Vacuum forming provided a more cost-effective, durable light-weight end result than fabricating this case from metal stampings
Product Description: Rugged light-weight thermoformed protective carrying case for use in military aviation.
Material: High Density Polyethylene (HDPE)
Secondary Operations: Perimeter routing, drilling, assembly/attachment of handles, hinges, and foam insert are completed after thermoforming is completed.
Dimensions: 28" x 18" x 8
Quantities: 500 per year
Production Notes: Vacuum forming provided a more cost-effective, durable light-weight end result than fabricating this case from metal stampings
Vacuum Formed Window Louver
Material: UV Capped ABS
Secondary Operations: Robotic trimming is performed after thermoforming.
Quantities: 1000 per year
Production Notes: Vacuum forming required less tooling than injection molding and provided superior design detail.
Material: UV Capped ABS
Secondary Operations: Robotic trimming is performed after thermoforming.
Quantities: 1000 per year
Production Notes: Vacuum forming required less tooling than injection molding and provided superior design detail.
Vacuum Formed Replacement Kitchen Sink
Material: ABS with acrylic cap for scratch resistance
Dimensions: 32" x 21" x 8"
Quantities: Prototype
Production Notes: Due to lower tooling costs, thermoformed prototypes were more cost effective than ceramic, fiberglass, or stainless steel.
Material: ABS with acrylic cap for scratch resistance
Dimensions: 32" x 21" x 8"
Quantities: Prototype
Production Notes: Due to lower tooling costs, thermoformed prototypes were more cost effective than ceramic, fiberglass, or stainless steel.
Vacuum Formed Bezel / Cover Panel
Product Description: Vacuum formed cover panel for airport security equipment
Material: FR Rated ABS
Secondary Operations: After completion of each thermoforming cycle, routing, drilling, assembly of bosses on backside, painting, and screen painting are performed in-house.
Dimensions: 36" x 30" x 10"
Quantities: 4,000 per year
Production Notes: Vacuum forming provided a better finish than molded fiberglass or stamped metal.
Product Description: Vacuum formed cover panel for airport security equipment
Material: FR Rated ABS
Secondary Operations: After completion of each thermoforming cycle, routing, drilling, assembly of bosses on backside, painting, and screen painting are performed in-house.
Dimensions: 36" x 30" x 10"
Quantities: 4,000 per year
Production Notes: Vacuum forming provided a better finish than molded fiberglass or stamped metal.
Vacuum Formed Hospital Gurney Wheel Base
Material: Vacuum Formed ABS
Secondary Operations: Robotic Perimeter Routing
Dimensions: 24" x 28" x 6"
Quantities: 500-1,000 per year.
Production Notes: Customer selected vacuum forming for cosmetic reasons.
Material: Vacuum Formed ABS
Secondary Operations: Robotic Perimeter Routing
Dimensions: 24" x 28" x 6"
Quantities: 500-1,000 per year.
Production Notes: Customer selected vacuum forming for cosmetic reasons.
Vacuum Formed Viewing Panel for Analyzing Equipment
Material: Vacuum Formed Smoked Acrylic
Secondary Operations: Robotic Trimming
Dimensions: 16" x 12" x 8"
Quantities: 300 per year
Production Notes: Fabrication using plastic sheet would have left visible, undesirable glued seams. Vacuum thermoforming also offered lower tooling costs than injection molding due to low production volumes.
Material: Vacuum Formed Smoked Acrylic
Secondary Operations: Robotic Trimming
Dimensions: 16" x 12" x 8"
Quantities: 300 per year
Production Notes: Fabrication using plastic sheet would have left visible, undesirable glued seams. Vacuum thermoforming also offered lower tooling costs than injection molding due to low production volumes.
Vacuum Formed Electric Motor Cover
Material: Vacuum Formed Black ABS
Secondary Operations: Routing, trimming.
Dimensions: 12" x 8" x 8"
Quantities: 3,500 per year
Production Notes: Vacuum forming replaced a housing previously fabricated from metal.
Material: Vacuum Formed Black ABS
Secondary Operations: Routing, trimming.
Dimensions: 12" x 8" x 8"
Quantities: 3,500 per year
Production Notes: Vacuum forming replaced a housing previously fabricated from metal.
Pressure Formed Portable Measuring Device
Material: ABS
Secondary Operations: Routing, drilling, riveting, printing, and detailed assembly.
Dimensions: 21" x 12" x 4"
Quantities: 300 per year
Production Notes: Customer considered injection molding, but due to low production volumes, pressure forming was a more cost effective production method.
Material: ABS
Secondary Operations: Routing, drilling, riveting, printing, and detailed assembly.
Dimensions: 21" x 12" x 4"
Quantities: 300 per year
Production Notes: Customer considered injection molding, but due to low production volumes, pressure forming was a more cost effective production method.
Vacuum Formed Decorative Panel
Product Description: This vacuum formed panel is part of a bar coding scanning station used in retail stores.
Material: Metallic Covered ABS
Secondary Operations: Routing and detailed assembly.
Dimensions: 72" x 18" x 10"
Quantities: 6,000 per year
Production Notes: Thermoforming provided better design detail features than using a stamped metal part.
Product Description: This vacuum formed panel is part of a bar coding scanning station used in retail stores.
Material: Metallic Covered ABS
Secondary Operations: Routing and detailed assembly.
Dimensions: 72" x 18" x 10"
Quantities: 6,000 per year
Production Notes: Thermoforming provided better design detail features than using a stamped metal part.
Vacuum Formed Storage Unit
Product Description: This vacuum formed storage unit is designed for use in cargo bay areas on SUV's.
Material: Black ABS
Secondary Operations: Routing, drilling, assembly.
Dimensions: 44" x 39" x 12.5"
Quantities: Thousands per year.
Production Notes: This vacuum thermoformed storage unit replaces heavier, more expensive metal storage systems.
Product Description: This vacuum formed storage unit is designed for use in cargo bay areas on SUV's.
Material: Black ABS
Secondary Operations: Routing, drilling, assembly.
Dimensions: 44" x 39" x 12.5"
Quantities: Thousands per year.
Production Notes: This vacuum thermoformed storage unit replaces heavier, more expensive metal storage systems.
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