Thermoforming   

Need a custom plastic shape that’s lightweight, open-ended, and repeatable? Or perhaps you need a specially shaped food-safe container? Thermoforming is a fantastic option.

Using heat and vacuum, we can shape thin sheets of plastic into molds, trays, housings, masks, and more. It’s great for everything from packaging to costume pieces to enclosures for electronics, and particularly good for food-safe trays and containers.

We can create the molds in-house from 3D prints or milled from wood composites, and then use that single mold to make as many copies as you’d like in a variety of plastics colors. If you're looking for a cost-effective way to make multiples of a part or get a smooth, professional look, thermoforming might be exactly what you're after.

Check out our gallery see the thermoformer in action (it’s so satisfying to watch), or just send us a note to see if it’s the right tool for the project you have in mind!

Thermoforming Limits

Thermoforming is a great technique for creating lightweight, hollow shapes, but it does come with some limitations. Since the process involves stretching a heated plastic sheet over a mold, it's best suited for smooth, rounded forms without undercuts or deep, narrow features. You can make things like trays, masks, shells, packaging, and housings—basically anything with one open side and a relatively shallow depth. Parts with fine internal details or sharp vertical walls are better suited for other methods like 3D printing or CNC machining. If you’re not sure whether your part is right for thermoforming, we’re happy to take a look and help you decide.