SealWerks provides product design and engineering services for custom RF welded and thermoformed products, helping manufacturers move from early concept to production-ready design. Whether you need flexible containment, soft goods, flexible packaging design, or rigid and semi-rigid components, our in-house team can help determine the right material, geometry, fabrication path, and quality requirements for your application.
Have a concept? Let’s engineer it together — request a custom design quote from our engineering team.
SealWerks is ISO 9001:2015 certified and will work with your team to assist with:
Our contract manufacturing product design support is built for B2B buyers, engineers, product managers, and OEM teams that need practical guidance before production begins. Bring us your idea, drawing, sample, or performance requirements — our design engineers will help turn it into a manufacturable solution.
With a team of design engineers and manufacturing experts, we fabricate your products at our manufacturing facility in Elk Grove Village, Illinois. Keeping everything in-house adds efficiency, improves communication, and helps maximize productivity throughout the design and manufacturing process.
You’ll also have peace of mind knowing you can pick up the phone or schedule a site visit and speak directly with the design and engineering team supporting your project. From material recommendations to prototype review and production planning, SealWerks provides practical, responsive support under one roof.
Our strong relationships with leading material suppliers can also help reduce time to market and support cost-effective production decisions. For larger-volume projects, custom material options may help reduce cost, improve performance, and support a more polished final product.
Our design and engineering team supports every stage of the development process, from early product concepts to production-ready drawings. If you have existing CAD files, prints, samples, or rough sketches, we can use them to evaluate manufacturability and recommend improvements. If you do not yet have a final design, we can help develop detailed CAD drawings to guide prototyping and production.
This support is especially valuable when a product’s material, geometry, or containment requirements determine whether RF welding, thermoforming, or another fabrication method is the right choice. Our product fabrication design services help identify potential manufacturing challenges early, before they become costly production issues.
When you submit your RFQ, include any available drawings, files, specifications, or performance goals so our team can review your design requirements efficiently.
Material selection is one of the most important decisions in custom product development. RF-welded products often require compatible films like PVC, laminates, coated fabrics, or other flexible materials that can form strong, sealed assemblies. Thermoformed products may require rigid or semi-rigid sheet plastics selected for strength, clarity, impact resistance, temperature performance, or chemical compatibility.
Our team provides material recommendations based on how your product needs to function, what it needs to contain, and how it will be used in the field. We consider containment needs, durability, flexibility, appearance, regulatory expectations, production volume, and cost targets.
Not sure which material fits your application? Tell us about your project and we’ll recommend the right fit.
Prototyping helps validate design assumptions before moving into production. SealWerks offers product prototyping services for custom RF welded and thermoformed products, allowing your team to review fit, function, material behavior, containment performance, and manufacturing feasibility.
For flexible sealed products, our RF welding prototyping services can help test seam placement, material compatibility, part geometry, and inflation or fluid containment needs. For thermoformed components, prototyping can help confirm shape, wall thickness, fit, rigidity, and end-use performance.
For thermoformed products, mold and tooling decisions directly affect part quality, repeatability, cost, and production efficiency. SealWerks supports thermoforming mold design for custom components that require consistent shape, fit, and performance. Our team evaluates part geometry, material behavior, draft angles, forming depth, trim requirements, and production volume when recommending a tooling approach.
Our mold design services can support new product development as well as improvements to existing thermoformed parts. We also assist with thermoform tooling design considerations that may impact manufacturability, including material thickness, tolerances, surface finish, and downstream assembly needs.
Tooling requirements vary by application, so the best next step is to share your product goals through the RFQ form. Our team will review your specifications and recommend the right tooling path for your project.
If an existing product is underperforming, difficult to manufacture, too expensive to produce, or dependent on outdated materials, SealWerks can help with product re-engineering. Our team reviews the current design, material selection, fabrication process, and performance requirements to identify practical improvements.
Re-engineering may involve changing materials, adjusting seam or part geometry, improving containment performance, simplifying assembly, reducing waste, or making a product easier to manufacture at scale. We also look for opportunities to improve consistency, production efficiency, and long-term reliability.
Learn more about our product re-engineering support.
Quality assurance begins during design, not after production. SealWerks integrates QA considerations early in the engineering process so each product can be manufactured to consistent standards. From material review and design validation to inspection and testing, our team works to reduce risk before your product reaches full production.
SealWerks is ISO 9001:2015 certified, giving customers confidence that our processes are documented, repeatable, and focused on continuous improvement. Depending on your product requirements, quality checks may include dimensional review, containment testing, visual inspection, material verification, or production sampling.
Learn more about our quality assurance program.
Product design and engineering are supporting disciplines that feed into the right fabrication process. Depending on your product’s material, geometry, and containment needs, our design team will recommend the right fabrication path — RF welding for sealed, flexible assemblies, and thermoforming or vacuum forming for rigid and semi-rigid components. We also support commercial sewing for soft-goods assembly.
That means you do not need to know the final process before you contact us. If you have a product idea, performance requirement, drawing, or sample, our engineering team can help determine which method best supports your application.
Quality products start with detailed designs, engineering insight, and the right fabrication path. Whether your project requires RF product design and engineering services, thermoforming mold design, product prototyping, re-engineering, or ISO 9001 quality assurance support, SealWerks can help you move from concept to quote.
Ready to bring your concept to life?
Product design engineering is the process of turning a concept, drawing, sample, or performance requirement into a product that can be manufactured consistently. It includes evaluating materials, part geometry, fabrication methods, tooling needs, prototyping, testing, and quality requirements before production begins.
For RF welded and thermoformed products, product design engineering helps determine the best way to achieve the product’s intended function. That may include selecting flexible films or coated fabrics for sealed RF welded assemblies, choosing rigid or semi-rigid plastics for thermoformed parts, or adjusting the design to improve durability, containment, manufacturability, and cost efficiency.
At SealWerks, our design engineers help customers move from “I have an idea or spec” to a practical, production-ready solution.
Sometimes. It depends on the part and project requirements. A finished drawing or CAD file may not be required to begin your custom RFQ. SealWerks can often start by reviewing rough sketches, product samples, photos, written specifications, performance requirements, material requirements, or an existing part that needs improvement.
For some projects, however, detailed technical drawings or CAD files are necessary to accurately evaluate manufacturability and quote tooling and production. If drawings are required and you do not already have them, SealWerks can provide design and drawing support as an additional service. Any associated engineering or design fees will be discussed before that work begins.
If you already have CAD files, technical drawings, or material specifications, our engineering team can review them for manufacturability and recommend the appropriate fabrication path. If your project is still in the early concept stage, we can help identify the materials, geometry, performance requirements, and production considerations needed to move it forward.
The more information you provide in the RFQ form, the more efficiently our team can evaluate your project and recommend the appropriate next steps.
You do not need to know the final fabrication method before requesting a quote. SealWerks’ design and engineering team will review your product’s material needs, geometry, containment requirements, flexibility, durability, and end-use environment to recommend the right process.
RF welding is often a strong fit for flexible products that require sealed seams, air or fluid containment, or durable soft-goods assemblies. Thermoforming is typically used for rigid or semi-rigid plastic components that need a defined shape, structure, or repeatable molded form. Some products may also require commercial sewing or a combination of fabrication methods.
By sharing your product goals through the custom design RFQ, our team can help determine the best path for your application.