SealWerks provides custom thermoforming services for manufacturers that need precision thermoplastic parts without the high tooling costs or long development timelines often associated with other plastic molding methods. Our plastic thermoforming capabilities support prototypes, medium-to-large volume production, and custom formed components used in medical, industrial, packaging, government, manufacturing, and military applications.
We work with engineering and product development teams to evaluate part geometry, material performance, tooling requirements, color needs, and production goals. Whether you need a thermoformed enclosure, tray, cover, protective component, housing, insert, or custom formed plastic part, SealWerks helps align the process with your application from concept through production.
Our thermoforming services include vacuum forming, pressure forming, material selection support, trimming, finishing, and production guidance for projects requiring durable, lightweight, and repeatable thermoplastic components.
Thermoforming is a plastic forming process that uses heat to shape thermoplastic sheet material over or into a mold. Once the plastic sheet is heated to a formable temperature, it is shaped using vacuum, pressure, or a combination of forming techniques. After cooling, the formed part retains its shape and can be trimmed, finished, assembled, or prepared for end use.
Compared to injection molding, thermoforming can offer lower tooling costs, faster development cycles, and greater design flexibility, especially for prototypes, custom components, and low-to-medium volume production. Because thermoforming tools are typically less complex than injection molds, design adjustments can often be made more efficiently during early project development.
Thermoforming is well-suited for producing precision plastic parts such as covers, trays, housings, panels, guards, enclosures, packaging components, and other custom thermoplastic parts where performance, fit, appearance, and cost all matter.
Thermoforming is not a single process. Different forming methods are used depending on part complexity, surface detail, dimensional requirements, material selection, and production volume. SealWerks supports multiple thermoplastic forming services and helps manufacturers select the right process for their application.
Vacuum forming is one of the most widely used thermoforming methods. In this process, a heated plastic sheet is drawn over or into a mold using vacuum pressure. Vacuum forming is commonly used for parts with simpler geometries, broad surfaces, and efficient production needs.
Vacuum forming is often a strong fit for:
This process is ideal when cost efficiency, faster tooling, and reliable repeatability are important project priorities.
Pressure forming builds on the vacuum forming process by applying additional air pressure to force heated plastic more tightly against the mold surface. This allows for sharper detail, improved definition, tighter radii, and more refined cosmetic surfaces.
Pressure forming services are often used when a thermoformed part needs to more closely resemble an injection molded component while still benefiting from thermoforming’s lower tooling costs and design flexibility.
Pressure forming may be a good fit for:
Many projects require more than a standard forming process. SealWerks provides thermoforming design and engineering support to help manufacturers evaluate part design, material behavior, tooling strategy, finishing requirements, and production feasibility.
Our team can support projects that begin with CAD files, drawings, prototypes, existing parts, or early-stage concepts. By reviewing the application requirements early, we help identify opportunities to improve formability, durability, fit, function, and manufacturability before production begins.
For projects that combine formed plastic with flexible materials, RF welding, sealing, or fabricated assemblies, SealWerks can also help evaluate how thermoformed components fit into the larger product system.
SealWerks follows a structured thermoforming process to help move projects from idea to production with fewer surprises.
Tooling plays a major role in thermoformed part quality, repeatability, cost, and lead time. The right mold approach depends on the part design, expected volume, material, tolerance needs, surface finish, and production timeline. Some types of tooling may have limitations related to part detail, durability, achievable tolerances, surface finish, or production volume, so selecting the appropriate tooling method is an important part of the design and quoting process.
Thermoforming tooling may be developed for:
During the quoting and design review process, SealWerks evaluates tooling requirements alongside material selection and part geometry. This helps determine the most appropriate path for producing consistent thermoformed plastic parts while managing cost and development time.
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| Tooling Option | Ideal For | Why Choose It |
|---|---|---|
| Cast Aluminum Production Tooling | Repeat production, complex part geometry, detailed surfaces, and longer-term production programs | Durable tooling designed for consistency and long service life. Cast aluminum can reproduce detailed contours and surface features. When water-cooled tooling is used, faster heat removal can also help improve production cycle efficiency. |
| Machined Aluminum (Billet) Machined Production Tooling | Repeat production, precision parts, shallower draw depths, and applications requiring durable, repeatable tooling | Machined from solid billet aluminum for strength, accuracy, and consistent production performance. A practical production option depending on part geometry, volume, and project requirements. |
| Machined Urethane/Board Tooling Prototype / Low Volume | Prototypes, design validation, lower-volume production, and projects where metal tooling may not yet be necessary | A practical, lower-cost option for evaluating geometry or producing limited quantities before committing to more durable production tooling. |
| 3D-Printed Tooling Prototype / Low Volume | Prototypes, lower-volume production, design development, and projects where tooling time or upfront investment is a priority | Created directly from a digital design, helping move efficiently from design to physical tooling while supporting complex shapes and controlled tooling costs. |
| Wood Prototype Tooling Early-Stage Prototype | Early prototypes, basic form evaluation, patterns, fixtures, and proof-of-concept work | An economical option for evaluating basic geometry and identifying design or manufacturability concerns before committing to more durable tooling. |
All custom thermoforming tooling remains the property of the customer. SealWerks stores customer-owned tooling at our facility for use in future production runs, helping support consistent part quality, repeatability, and efficient reordering. When additional parts are needed, your existing tooling is readily available for production without the need to recreate the tool.
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Activity
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Tolerance
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Guideline
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|---|---|---|
Formed Measurements
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±0.0230" | Additional ±0.0012" per inch beyond 12" |
Drilled Hole Diameters
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±0.0058" | Holes equal to or less than 1" |
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Drilled Hole Diameters
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±0.0115" | Holes from 1" to 5" |
Slots
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±0.0115" | Slot equal to or less than 1" in any direction |
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Slots
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±0.0230" | Slots greater than 1" |
5 Axis Trim
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±0.0173" | Trim features under 5" |
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5 Axis Trim
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±0.0230" | Trim features greater than 5" |
Hand Trim General
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±0.0713" | Trim guides molded into form |
Hand Trim Hole Diameter
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±0.0230" | Blind drilled on dimples or jig-assisted |
The right material depends on the part’s function, environment, appearance, and production requirements. SealWerks works with a range of thermoformable plastics and helps manufacturers select the best option for their application.
| Material | Common Benefits | Typical Uses |
|---|---|---|
| ABS | Strong, rigid, impact resistant, available in many colors and textures | Housings, covers, panels, equipment components |
| HIPS | Cost-effective, easy to form, available in multiple colors | Packaging inserts, displays, trays, signage |
| KYDEX® Thermoplastic Sheet | Durable, impact- and chemical-resistant, excellent formability: available in a variety of colors, textures, and finishes; maintains detailed shapes and dimensional stability. | Equipment housings and enclosures, medical components, protective covers, panels, trays, and other formed industrial components. |
| PETG | Clear, impact resistant, easy to form, available in medical-grade options | Medical packaging, protective covers, display parts |
| Polycarbonate / PC | High impact strength, clarity, temperature resistance | Protective components, guards, electronic housings |
| HDPE | Chemical resistant, impact resistant, durable in cold environments | Containers, industrial components, outdoor applications |
| PVC | Strong, versatile, available in rigid and flexible forms | Signage, panels, electrical and industrial components |
| Polypropylene / PP | Chemical resistant, lightweight, good temperature performance | Medical disposables, food-related components, containers |
| TPO | Impact resistant, available in high-gloss finishes, outdoor capable | Automotive parts, protective covers, outdoor components |
| PC/ABS | Combines impact strength and processability | Equipment housings, electronic enclosures, durable covers |
Material thickness, part size, draw depth, geometry, and finishing needs are evaluated early to ensure the selected plastic performs properly during forming and in the final application.
SealWerks can help source thermoformable plastic sheet materials in a range of colors, textures, and finishes depending on the selected material, supplier availability, production volume, and application requirements.
Color and texture options vary by material, with some thermoforming plastics available in standard opaque colors like black, white, or gray and others offering 60+ color choices, including custom color options. We source thermoforming materials from trusted suppliers such as Curbell Plastics, Piedmont Plastics, and KYDEX® to help match the right color, finish, and texture to your application.
*All materials, textures, and finishes are dependent upon material type.
Thermoforming is used to create a wide range of functional, protective, structural, and cosmetic plastic components. SealWerks supports custom thermoforming applications such as:
By separating application needs from industry requirements, SealWerks can help match the right material, forming process, and finishing approach to the part’s actual function.
SealWerks provides custom thermoforming services for manufacturers and organizations across demanding industries where quality, consistency, and application-specific performance are essential.
Medical thermoforming applications often require cleanable materials, dimensional consistency, protective packaging, and compatibility with device or equipment requirements. SealWerks supports thermoformed medical trays, sterile barrier packaging components, equipment covers, diagnostic device housings, and protective parts used in healthcare environments.
For medical projects, we help evaluate material selection, part geometry, cleanability, production repeatability, and documentation needs. If your project requires specific medical-grade materials or certification requirements, our team can review those specifications during the RFQ process.
Industrial environments require thermoformed plastic parts that can withstand impact, chemical exposure, repeated handling, and demanding operating conditions. SealWerks produces industrial thermoformed components such as machine guards, covers, shrouds, panels, trays, and protective parts designed for long-term performance.
Our team helps match material properties such as impact resistance, chemical compatibility, UV stability, rigidity, and temperature tolerance to the conditions of your facility or equipment.
Thermoforming is widely used in packaging because it can create lightweight, protective, and repeatable plastic components with efficient tooling. SealWerks supports packaging applications such as trays, inserts, blisters, protective shells, clamshell-style components, and custom packaging forms.
Packaging projects may require clarity, product protection, material compatibility, clean presentation, or repeatable fit. SealWerks can help evaluate PETG, HIPS, PVC, and other materials depending on the packaging application.
SealWerks works with manufacturers to develop thermoformed parts that integrate with existing workflows, production lines, equipment, and assembly processes. Our custom thermoforming services can support prototype validation, replacement parts, and production-ready components.
Government projects may require specialized thermoformed components for equipment protection, containment, infrastructure, transportation, or field-use applications. SealWerks supports government thermoforming projects where durability, documentation, repeatability, and specification alignment are important.
Our team can review project requirements, material needs, procurement considerations, and part performance expectations during the quoting process.
Military thermoforming applications often require lightweight strength, impact resistance, environmental durability, and reliable performance in demanding conditions. SealWerks supports custom military thermoforming projects such as ruggedized enclosures, protective covers, field equipment components, vehicle-related parts, and mission-specific plastic components.
When required, we can help evaluate materials and design considerations related to impact strength, environmental exposure, sealing compatibility, and long-term durability.
Custom thermoforming offers several advantages for manufacturers developing precision plastic parts.
Thermoforming tooling is typically less complex and less expensive than injection molding tooling, making it a cost-effective option for prototypes, custom parts, and low-to-medium volume production.
Because thermoforming tools can often be produced and modified more quickly, the process can support faster prototyping, validation, and design iteration.
Thermoforming allows teams to evaluate part shape, fit, function, material behavior, and appearance before committing to more expensive tooling or higher-volume processes.
Thermoformed plastic parts can provide strong performance while remaining lightweight, making them useful for protective covers, enclosures, trays, guards, and handling components.
Thermoforming supports many plastic materials, including ABS, PETG, HDPE, HIPS, polycarbonate, PVC, polypropylene, TPO, and PC/ABS. This allows parts to be matched to specific performance and appearance needs.
Thermoforming can support early prototypes, pilot runs, and production volumes, helping manufacturers maintain continuity as project requirements evolve.
For unique or application-specific parts, custom thermoforming gives manufacturers more control over geometry, material, color, surface finish, and end-use performance.
Many thermoforming projects begin with a prototype, proof of concept, or early validation run. SealWerks supports this process by helping manufacturers evaluate design feasibility, material performance, tooling approach, and forming method before final production requirements are locked in.
As the design matures, we help guide the transition into production with attention to repeatability, process stability, finishing requirements, and quality expectations. Tooling refinements, material behavior, trim details, and assembly considerations are reviewed to reduce issues before production begins.
By supporting both development and production phases, SealWerks provides continuity throughout the lifecycle of a custom thermoforming project.
Choosing the right thermoforming company is about more than forming plastic. Manufacturers need a partner that understands design requirements, material behavior, production constraints, documentation needs, and downstream assembly considerations.
SealWerks offers:
If you are researching a thermoforming project, validating a new product design, or sourcing a thermoforming manufacturer for production, SealWerks can help. Our team provides thermoplastic forming services that support part development, material selection, forming, finishing, and production planning.
Submit your project details, drawings, CAD files, material requirements, or application notes today. We welcome RFQs at any stage of development.
Thermoforming is the broader category of plastic forming processes that use heat to shape thermoplastic sheet material over or into a mold. Vacuum forming is one type of thermoforming that uses vacuum pressure to pull heated plastic against the mold surface.
Vacuum forming uses vacuum pressure to shape heated plastic over or into a mold. Pressure forming adds air pressure to create sharper detail, improved surface definition, and more refined cosmetic features. Pressure forming is often used when a part needs greater detail than standard vacuum forming can provide.
Thermoforming is often a better option when tooling cost, speed, flexibility, or low-to-medium volume production are priorities. It is also useful for prototyping and design validation before investing in more expensive injection molding tools.
Common thermoforming materials include ABS, HIPS, PETG, polycarbonate, HDPE, PVC, polypropylene, TPO, and PC/ABS. The best material depends on the application’s impact resistance, stiffness, temperature exposure, chemical compatibility, color, clarity, and finish requirements.
Yes. Many thermoformable plastics are available in a range of colors, textures, and finishes. Color availability depends on the material, sheet supplier, production volume, and application requirements. SealWerks can help evaluate color and finish options during material selection.
Yes. Thermoforming is commonly used for medical trays, packaging components, equipment housings, protective covers, and device-related parts. Material selection, cleanability, consistency, and documentation requirements should be reviewed early for medical thermoforming projects.
Yes. Thermoforming can be used to produce lightweight, durable, impact-resistant plastic parts for military and field-use applications. These may include protective covers, ruggedized enclosures, equipment components, and application-specific plastic parts.
A helpful thermoforming RFQ includes part drawings or CAD files, material requirements, expected production volume, color or finish needs, performance requirements, environmental exposure, target timeline, and any applicable quality or documentation requirements.
Yes. SealWerks supports thermoforming projects from early prototypes and design validation through production. Early involvement helps identify material, tooling, and design considerations before production begins.