Archive for Company News

Manufacturing the Team to Provide you with the Best Plastic Thermoforming Solutions

Manufacturing the Team to Provide you with the Best Plastic Thermoforming Solutions

I am pleased to announce the addition of Cody Brewer as our Business Development Manager to the team at Productive Plastics.

Cody has over 7 years of experience in the process engineering and sales industry, with the greater part of his career invested in manufacturing process improvements and supporting production and engineering operations. His diverse experience in disciplines paramount to our industry enable Cody to provide insight and guidance to customers during the entire development process; from product design to finished components in your hands.

Cody will be working closely with myself and the rest of the Productive Plastics team to bring you the highest level of service, quality manufacturing, product development, and rapid solutions for the production of custom plastic thermoformed components and assemblies.

I invite you to connect with Cody to discuss how Productive Plastics can contribute to your project’s success.

John Zerillo
VP Sales | Productive Plastics

Cody Brewer
Business Development Manager
Productive Plastics
103 West Park Dr
Mt Laurel NJ, 08054
Cell: 1-(609)-280-0040
Office: 1-(856)-778-4300 Ext. 202

2018 Plastic Thermoforming Product Development Summit

Plastic Thermoforming Summit Registration Register Now for the Plastic Thermoforming Product Development Summit



At the 2018 Plastic Thermoforming Product Development 3D Printer Giveaway During SummitSummit, hosted by Productive Plastics, you will learn about every aspect of developing a new product or converting an existing project to the plastic thermoforming manufacturing process.You will gain insights about the entire development process, from design to finished assembly, as you engage with industry leaders from each link in the production supply chain.


What to Expect

  • Summit kickoff with networking, coffee, and a continental breakfast
  • Technical presentations from experts in plastic thermoforming manufacturing, thermoplastic materials, industrial design, industrial finishing, tooling and mold construction, and structural adhesives and bonding
  • Catered lunch
  • Q&A panel
  • Chance to take home a 3D printer

Actionable Takeaways

  • An in-depth understanding of the features, benefits, and limitations of the heavy gauge plastic thermoforming process
  • The knowledge to make a clear assessment of when thermoforming is the right solution for your application
  • How thermoforming compares to production processes such as fiberglass, metal, injection molding, and others
  • Technical knowledge and pro tips on how to design your application to take full advantage of the benefits of plastic thermoforming
  • Key considerations and capabilities of post production processes such as finishing, attachment point bonding, and assembly

Who Should Attend

  • Designers
  • Engineers
  • Procurement
  • Product Development Team Members
  • OEM Design and Development Contributors

Date & Time:


June 20th 2018

8:00am – 3:00pm


Natick Boston-Metro West

Courtyard by Marriott Boston Natick

342 Speen Street

Natick, MA 01760



$50 Registration


Chance to win a 3D printer

Continental Breakfast/Coffee

Catered Lunch


Custom Plastic Thermoforming

John Zerillo

VP Sales | Principal

Productive Plastics

Extrusion Process and Material Selection

Eric B. Lattanner

Business Development Manager


Design for Thermoforming Key Considerations

Scott Ryan, IDSA


Brownlie Design

Tooling Development

Fritz Borke

Borke Mold and Bay State Cast Products

Industrial Finishing

John Snyder

PPG Paints

Structural Adhesives and Tapes

John Petrauskas

Ellsworth Adhesives (ITW)

Register Now for the Plastic Thermoforming Product Development Summit



Seasons Greetings – Help Productive Plastics Spread Holiday Cheer!

Productive Plastics is looking for your help. In a effort to provide you with better solutions for your custom plastic thermoformed parts and projects, we reach out to professionals in the industry each year, seeking feedback on your experiences with either our company or other custom manufacturers.

Seasons Greetings 670 banner

We have put together a short 5 minute survey that will help us understand what facets of the custom component manufacturing process are key contributors or challenges to the success of your projects.

In recognition of your time and in the spirit of giving this time of year, Productive Plastics will make a $5 donation tothe Lifesong for Orphans organization for every completed survey.

Your feedback matters and has a direct impact on how we do business

– Expanding manufacturing, material, and engineering capabilities

– Investment in new technologies

– Pricing structure adjustments

– Quality control improvements

– Lead time reducing process improvements

– Customer service and support communication

All and more are influenced by your responses.

We want to hear from you

– Owners and C-suite Executives

– Design, Project, and Sustaining Engineers

– Quality Assurance

– Project Management

– Buyers / Commodity Managers

Your input will help the team at Productive Plastics provide better solutions to your custom plastic thermoforming needs and support a truly charitable organization. Thank you in advance for your help.

Lifesong for Orphans is a faith based organization that helps orphan children in need all over the world. Please visit their website for more information on this amazing organization.

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(Productive Plastics will donate $5 to the Lifesong for Orphans organization for every survey completed up to a maximum of $1000. One survey completion per person and/or computer will be counted for donation purposes)

Thermoforming at Its Best Article Features Productive Plastics

Productive Plastics was recently featured in the February 2016 edition of Business in Focus magazine. The article describes Productive Plastics as an industry leader in heavy gauge plastic thermoforming, highlighting the company’s manufacturing capabilities, quality and efficiency processes, history, values, and commitment to customer value. View this “Thermoforming at its Best” article on the Business in Focus website.

Productive Plastics featured in Business in Focus

An excerpt from the article:

Productive Plastics has grown into an industry leader, always in pursuit of excellence and profitable growth. It differentiates itself by focusing on core values of honesty, integrity, respect, and fairness and by investing in its people and processes. These values have served as a cataylst for generations of growth and success in the family-owned and managed company.

For additional press releases or news about Productive Plastics, visit recently updated News Room and Recognition page.

Productive Plastics is top contract manufacturer for heavy gauge thermoforming, including vacuum forming and pressure forming. Contact us or request our complimentary thermoforming design guide for more information.

Please contact Productive Plastics for more information on the thermoforming process
Please download our complimentary thermoforming design guide for more information on the thermoforming process

Productive Plastics Presenting at SPE European Thermoforming Conference March 2016

Productive Plastics will be presenting at the Society of Plastics Engineers European Thermforming Division Conference on March 11, 2016 at 8:45am in Sitges (Barcelona), Spain.

Productive Plastics presenting SPE Europe

Lean Manufacturing – Proof that the ‘Old Way’ isn’t always the best Way!

If you will be attending the conference, please join Evan Gilham, Productive Plastics COO, as he shares the benefits and advantages to both the customer and the manufacturer in embracing a lean and smart manufacturing culture.

Evan will examine a number of case studies, tools, and techniques that have proved successful in producing a very efficient and streamlined design and manufacturing process at Productive Plastics. View the conference program and schedule for program information.


Not attending the show this year?

Stay tuned to the Productive Ideas blog as we release highlights of Evan’s presentation on the benefits of lean manufacturing and smart production techniques.

Please take our industry survey and help us spread some holiday cheer

This survey has been completed and is now closed. Thanks to the many participants.

Seasons Greetings

Productive Plastics values your input and would like to provide you with the best service and thermoforming solutions. Please help us by participating in our industry survey (less than 5 min) and join us this year in spreading some holiday cheer. In recognition of your time, Productive Plastics will donate $5 to the Lifesong for Orphans organization for every survey submitted. (Max $500) Thank you in advance for your time and input.

Happy Holidays!


Productive Plastics Brings Two Top Awards Home from SPE Thermoforming 2015

Productive Plastics is honored, humbled, and proud of our dedicated and hard working team members to again be recognized at the Society of Plastics Engineers (SPE) Thermoforming Division Conference this year with two top awards in the parts competition.


Below is an excerpt from the PLASTICS TODAY article by Clare Goldsberry covering this year’s conference.

The 24th Annual SPE Thermoforming Conference, held in Atlanta last week, provided real proof of just how far that industry has come since 1991. The parts competition in the cut-sheet/heavy-gauge section gave attendees cause for pause, as they looked in amazement at the parts. It was quite different from the first few conferences, held in small hotel venues with tabletop exhibits where most of the parts fit nicely on a few tables.

Over the years, as the conference got larger, so did the parts. One area of the thermoforming industry that has expanded is large-part forming using heavy-gauge sheet. Applications for this process include everything from pickup-truck bed liners to dental chair bases to automotive hoods and medical equipment, MRI machines to be specific.

According to a recent report from Peter Mooney, President of Plastics Custom Research Services (Advance, NC), medical equipment enclosures are increasingly becoming a big part of the thermoforming industry’s business. In fact, many of the large parts being produced today have been converted from injection molding to thermoforming, which is ideal for lower part quantities.


Gold Award – Heavy Gauge Value Added Category

MRI Scanner

Part Details:

Utilizing Self Moulding for tooling all 8 parts where pressure formed utilizing a Cast and machined mold.  In order to achieve the customer’s distribution of materials requirement all parts utilized pushers to pre-stretch materials.

Using Sekisui’s materials parts where produced in Kydex T.  The material allowed for the wall thicknesses required and consistency over multiple runs and hundreds of parts both in production and field replacements.

The 8 parts are using undercuts and formed in mating edges for better line to line fit up.  Cast and then CNC cut tools allowed for the precision required to have the assembly fit up after design.  The assembly allows for the parts to fit a separate metal frame that comes together at a staging location.  This custom hardware reduced the amount of tools required to install and service, and reduced the total time required for install and service (sample does not show hardware due to customer request).

The covers are painted using a PPG High Gloss Paint system.  This required a controlled environment that eliminated dust and the paint equipment had to be specially configured to eliminate debris.  Regular maintenance processes keep the line able to reproduce an 85 degree plus gloss finish.  The center bore represent a finished paint process that eliminates all surface imperfections related to paint and increased the gloss to 98 degrees.


Silver Award – Heavy Gauge Pressure Forming Category

Automated Diagnostic System

Automated Diagnostic Assembly

Part Details:

Utilizing Baystate Casting and Borke Mold for tooling all 3 parts where pressure formed utilizing a textured mold.  In order to achieve the customer’s distribution of materials requirement both parts utilized pushers to pre-stretch materials.

Using Sekisui’s materials parts where produced in Kydex T. The material allowed for the wall thicknesses required and consistency over multiple runs and hundreds of parts both in production and field replacements.

The design of the kiosk had the part fitting to a metal skeleton that required +/- .020 geometric tolerances for the attachment.  The full assembly is 7 different parts, this display is showing 4 of those parts.

All of these three pieces utilize undercuts to make formed in seams.  Due to the depth of the location of the undercut the tooling loose pieces had to be temperature controlled to reduce the effect of warpage during processing.

The paint is a Sherwin-Williams custom color masked off to only paint select areas.


Both entries demonstrate Productive Plastics’ long-standing expertise in contract manufacturing for the medical diagnostics equipment industry, where there can be many engineering challenges,” stated Evan Gilham, Productive Plastics COO. “So we really appreciate the recognition from SPE for our work with these medical heavy gauge thermoforming projects.

See our press release for additional details.


Productive Plastics Presenting at IDSA Medical Design Conference 2015

Productive Plastics presenting IDSA blog ver

Productive Plastics is pleased to host and present at the IDSA Medical Design Conference breakfast event this year.

Product Development Collaboration: A Design for Success

Will you be at this year’s conference? If so, please join Productive Plastics Principal and VP of Sales, John Zerillo, for breakfast as he explores the importance and benefits of product development collaboration between OEM, Design, and Manufacturing resources. John will discuss and present case studies on how faster time to market, fewer development pitfalls, and seamless design to finished product compatibility are all achievable outcomes resulting from collaborative efforts that begin in the early design stages of a project.

Productive Plastics Breakfast and Seminar

IDSA 2015 Medical Design Conference

Thursday, October 22nd

8:00– 8:45am

Dining Room

Center for Advanced Medical Learning and Simulation (CAMLS)

Seating is limited



Productive Plastics Presenting at SPE Annual Thermoforming Conference

Productive Plastics will be attending and presenting at the 2015 SPE Thermoforming Division Conference in Atlanta later this month.

Productive Plastics presenting at SPE Thermoforming Conference Aug 2015

Parts Competition

Productive Plastics has been hard at work to replicate our success in previous part competitions (2011 SPE Thermoforming Conference Awards) This year we will be showcasing 3 high quality, complex, and innovative heavy gauge thermoforming parts that are the culmination of our industry leading engineering, manufacturing, and solutions providing team at Productive Plastics. Submitted parts represent the Medical Device and Kiosk industries.

Productive Plastics Technical Presentation

COO Evan Gilham will be presenting at the conference at 10am on Wednesday, Sept 2nd, on Using Another Processor’s Tools – A Look into Tooling Comparison and Spec Sheets.

Click for more info on the presentation.

If you are attending the conference, please stop by our display at the Parts Competition or join Evan for his presentation on Wednesday.


COO Evan Gilham brings his expertise to Sales and Marketing

Effective May 1, 2015 it is with great pride that I announce the appointment of Evan Gilham to Sales and Marketing Manager in addition to his Chief Operating Officer position.


sales and marketing big

This is a result of our growth and plans for expanding the commitment for excellence.  Evan joined Productive Companies eight years ago and has been successful in developing IT Production, Procurement, and other Executive positions resulting in his transition to grow our companies.

Evan will now be responsible for the management of sales and marketing in Productive Plastics and Sensigraphics along with all operations at Productive Companies.  His executive team has developed a world class organization in quality, lean manufacturing, procurement, and advance production to the forefront of the best in technology.

Please welcome Evan to this new responsibility and feel free to discuss a mutual goal to provide a successful transition to better service our valued customers.

Thank you for your continued support!


Hal Gilham

Harold S. Gilham