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Thermoforming

Explore a Custom Thermoformed Part and See What’s Possible

Wednesday, March 18, 2026
Categories: Converting to Thermoforming, Technical, Thermoforming

What can modern custom thermoforming manufacturing really achieve?

This interactive 360 degree image of a pressure thermofomed car wash kiosk enclosure manufactured at our facility highlights the advanced capabilities available when working with Productive Plastics and the plastic thermoforming process.

When you interact with the part, you’ll see how we combine:

Explore the part front to back, click on the integrated feature hot spots to learn about specific capabilities and advantages, and see how advanced thermoforming manufacturing can offer solutions and streamline your next design with Productive Plastics.

*** You may need to scroll down the linked webpage to find the interactive 360 image if your email client does not support link to highlight **

Click to Explore the Custom Thermoformed Enclosure Now

Plastic Thermoforming Solutions for Your Industry

Tuesday, May 27, 2025
Categories: Converting to Thermoforming, Industries, Material Handling, Medical, Thermoforming, Transportation Interiors

At Productive Plastics, we specialize in custom plastic thermoforming and vacuum forming solutions that deliver lightweight, durable, and cost-effective enclosures and component solutions with major advantages for a wide range of industries. Our heavy-gauge plastic manufacturing process, secondary assembly, and surface finishing operation ensure high-performance parts designed to meet the specific needs of your industry and application.

Precision Thermoforming for Specific Applications

Below is a list of a few industries in which thermoplastic material and custom plastic thermoforming can offer unique advantages over other processes and also provide superior product solutions that are tailored to your industry. Find your industry below and follow the links to explore industry specific interactive examples, applications, and additional information to help you discover how custom plastic thermoforming can add to the success of your next project.

*The industries below are not a comprehensive list of all the applications that can benefit from custom plastic thermoformed components. View our website or reach out to one of our thermoforming experts to explore/evaluate how we can assist with your project.

Rail Car Transportation Interiors

Advantages:  Lightweight and fire retardant material (FST, Doc 90 and FMVSS 302 compliant), easy to clean, UV and graffiti resistant, large part capable, engineered for durability

Examples: Wall paneling, seating components, window shrouds, display enclosures, luggage racks, and more.

SOLUTIONS FOR RAIL INTERIORS

Medical Device Enclosures

Advantages: FDA-compliant, UL 94 V-0,  high gloss (class A) finishes, easy to clean, aesthetic design geometry and large part capable, impact-resistant

Examples: CT & MRI enclosures, diagnostic device enclosures and parts, patient bed components, ultrasound equipment, and more

SOLUTIONS FOR MEDICAL DEVICE

Mass Transit/Bus Interiors

Advantages:  Lightweight and fire retardant material (FST, Doc 90 and FMVSS 302 compliant), easy to clean, UV and graffiti resistant, large part capable, engineered for durability

Examples: Wall paneling, seating components, window shrouds, display enclosures, luggage racks, and more.

SOLUTIONS FOR BUS & MASS TRANSIT

 Aerospace Interiors 

Advantages:  Lightweight and fire retardant material (FST, FAR 25.853 (a), (i), (ii), & (d)), easy to clean, UV and graffiti resistant, large part capable, engineered for durability

Examples: Custom seating components, window shrouds, display enclosures, tray table assemblies, luggage racks, and more.

SOLUTIONS FOR AEROSPACE & AIRCRAFT CABINS

Robotic and Autonomous Systems and Vehicles

Advantages:  Lightweight and impact resistant material, aesthetic and complex design geometry capable, high gloss finishes and surface branding options, UV resistant material

Examples: UAV, UGV, UUV, and ROV enclosures and components, robotic and POS retail automation, humanoid and quadruped robotic components, and more.

SOLUTIONS FOR ROBOTIC AND AUTONOMOUS SYSTEMS

Converting Fiberglass to Plastic Thermoformed Parts: Advantages and Comparisons

Monday, December 02, 2024
Categories: Plastic Thermoforming vs Fiberglass, Thermoforming

In the realm of manufacturing, constant innovation is not optional. Industries are continually seeking methods to enhance efficiency, reduce costs, and improve product quality. One significant trend in this pursuit, especially for mass transit, railcar, and aerospace industries, is the transition from traditional fiberglass manufactured parts to plastic thermoformed components. This shift is not only cost driven but grounded in tangible advantages from weight reduction and enhanced durability to adherence to industry standards and sustainability.

Cost Efficiency

Fiberglass manufacturing involves complex processes, including molds, resins, and curing, which can be both labor and resource-intensive. Conversely, plastic thermoforming simplifies production processes, significantly reducing labor costs and material waste. Thermoforming allows for efficient batch production, rapid prototyping, and customization without hefty tooling expenses. These cost advantages are particularly beneficial for industries seeking competitive pricing without compromising on quality.

Weight Reduction

In an era where fuel efficiency and environmental sustainability are paramount concerns, reducing component weight is crucial across various sectors. Plastic thermoformed components offer a lightweight alternative to fiberglass counterparts, contributing to improved fuel economy in transportation applications and enhanced portability in consumer products. The inherent lightweight nature of thermoformed plastics translates to lower shipping costs and less strain on infrastructure, making it an environmentally friendly choice.

Enhanced Durability

While fiberglass has a reputation for its durability, plastic thermoformed components have emerged as formidable contenders in this aspect. Modern advancements in polymer science have led to the development of high-strength plastics that rival or even surpass fiberglass in terms of durability and impact resistance. These thermoformed plastics exhibit superior weatherability, corrosion resistance, and dimensional stability, ensuring longevity and reliability in diverse operating conditions. From outdoor equipment to automotive interiors, thermoformed plastics offer robust solutions that withstand the test of time.

 Compliance with Industry Standards

In many industries, adherence to stringent regulatory standards and certifications is non-negotiable. Plastic thermoformed components provide manufacturers with a competitive edge by offering thermoplastic material options that are compliant with transportation, aerospace, and other industry requirements for  fire, smoke, and toxicity (FST) standards such as SMP800-C, FDA regulations for food contact, UL certifications for electrical safety, and ASTM standards for performance testing.

For a more technical comparison of plastic thermoformed and fiberglass parts (including a downloadable guide and webinar recording), please follow the link below to visit our dedicated fiberglass vs. thermoforming webpage or contact our team of thermoforming experts directly

Exploring the Benefits of Plastic Thermoforming for Medical Device Manufacturing

Monday, February 13, 2023
Categories: Medical, Thermoforming

What is Plastic Thermoforming and How Does it Benefit Medical Device Manufacturing?

Plastic thermoforming is a manufacturing process that uses heat and pressure to form thermoplastic material into desired shapes. It is a popular method used in the production of medical devices, as it offers numerous advantages over other traditional manufacturing techniques such as injection molding, fiberglass, and sheet metal. The process can be used to create complex, intricate parts with tight tolerances and superior surface finishes, while also allowing for cost-effective production runs. In addition, plastic thermoforming can be used to produce parts with unique features such as integrated hinges and snap-fit components, and bonded attachment hardware. By utilizing these techniques, medical device manufacturers can create high-quality products that meet the stringent requirements of their industry.

The Advantages of Using Plastic Thermoforming for Medical Device Manufacturing

Plastic thermoforming offers many advantages in medical device manufacturing, including cost effective large parts, tight tolerances, industry compliant material, and improved product consistency. Thermoforming can produce high quality, complex, and aesthetically designed medical device parts for everything from device enclosures and paneling to laboratory equipment components and patient bed parts.

Siemens medical device enclosure – pressure formed, surface finished, branding applied, and attachment hardware bonded all at Productive Plastics

Use your mouse or touch screen to interact with and rotate the pressure formed part image. Don’t forget to click on the red hot spots to learn more about the unique thermoforming features of this part.

What are the Different Types of Plastic Thermoforming Processes?

Plastic thermoforming is comprised of two different subtype processes, vacuum forming and pressure forming that can be used in medical device manufacturing. Each type of process has its own advantages and disadvantages depending on the application. Vacuum forming is often used for creating large parts with complex geometries while pressure forming is often used for producing small parts with intricate details.

Choosing the Right Type of Plastic Thermoforming Process, Material, and Custom Thermoforming Manufacturer

When it comes to producing medical devices, the type of plastic thermoforming process, thermoplastic material, and custom thermoforming manufacturer you choose are critical decisions. With so many options available, it’s important to understand the advantages and disadvantages of each process and how they can meet your specific production needs. Finding a plastic thermoforming manufacturer with experience in the medical device manufacturing field that can assist with matching your project to the ideal process, material, secondary assembly, and surface finishing options can play a pivotal role in the ultimate success of your project.

Unlock the Benefits of Plastic Thermoforming for Medical Device

Productive Plastics has extensive experience producing custom multi-part component assemblies for numerous industry leading medical device manufacturers. We strive to be a trusted advisor throughout the entire product development process from prototype design through the final delivery of your thermoformed components or assembly. Our highly skilled engineers, manufacturing technicians, and support staff will work with your team to develop the right design, material, and process for your medical device project. Maximizing the advantages of plastic thermoforming and minimizing the cost and production time for your product.

Please visit our Custom Thermoforming for Medical Device page or contact our team to explore plastic thermoforming for your next medical device project.

Additive Manufacturing Advancing Custom Thermoforming at Productive Plastics

Sunday, January 22, 2023
Categories: Company News, Thermoforming

Productive Plastics featured on formlabs’s blog – 3D printed innovations for thermoforming

Productive Plastics was honored to be featured on the formlabs industry blog on January 12th, Problem Solving on the Factory Floor: Manufacturing Aids at Productive Plastics. The article highlights some of the tech and innovations we employ on the manufacturing floor, in particular, our utilization of in-house 3D printed manufacturing accessories to increase process efficiency, reduce lead times, and  maximize the benefits of manufacturing parts and enclosures with plastic thermoforming. All part of our commitment to provide our customers with the highest quality and most cost-effective custom thermoforming solutions in the industry.

Read the rest of the post for more info

Antimicrobial Plastics for Thermoforming Manufactured Custom Components

Sunday, January 08, 2023
Categories: Technical, Thermoforming, Thermoforming Material, Uncategorized

The demand for antimicrobial plastics has risen in recent years as yet another countermeasure to bacterial and viral health threats, such as COVID-19. As a result, plastic and thermoplastic material suppliers have responded by producing a wide range of thermoplastic sheet options, used in the plastic thermoforming manufacturing process, that posses antimicrobial properties and other benefits advantageous to a wide range of industries, not just healthcare.

What is antimicrobial plastic?

Antimicrobial plastics are produced with an additive in the base polymer designed to block the growth of microorganisms, including bacteria, mold, and fungi. The additive integrates into the structure of the plastic, so this benefit exists for the entire product life. These materials are generally measured using ISO 22196:2001 and/or JIS Z 2801 Standards. These antimicrobial additives can also provide an addition benefit to the longevity and structural integrity of a component by protecting against plastic material damaging bacteria that can, over time, degrade certain types of plastic.

Common Antimicrobial Additives for Thermoplastic

  • Microban™
  • Silver
  • Copper
  • Zinc
  • Phenolics

Antimicrobial Advantages for Thermoplastic

  • Inhibiting surface growth of bacteria, mold, and fungi
  • Durability – Bacteria may break down polymers over time, by blocking the growth, these additives may provide greater longevity.
  • Reducing odor/discoloration
  • Surface antimicrobial protection between cleanings
  • Antimicrobial protection for the duration of product life

Antimicrobial Thermoplastic Material Datasheets

Below are just a few examples of antimicrobial materials available for plastic thermoformed components

Antimicrobial Industry Applications

Custom Plastic Thermoformed Components with Antimicrobial Properties at Productive Plastics

Productive Plastics has experience working with antimicrobial plastics and long standing relationships with industry leading thermoplastic material suppliers. Our experts can advise you and your team on selecting the ideal thermoplastic to meet the performance demands of your next project. Please contact us to get started!

Contact Us

Thermoforming for Multi-Part Assemblies – Webinar Recording Available

Wednesday, December 07, 2022
Categories: Technical, Technical Thermoforming Webinar, Thermoforming, Uncategorized

If you were unable to attend our technical webinar this week on the capabilities and advantages of Thermoforming for Mult-Part Assemblies, a recording of the live event is now available on our YouTube channel.

WATCH THE RECORDING NOW

Here is what was covered in the webinar:

  • Vacuum vs Pressure Forming
  • Material Considerations
  • Application to match process
  • Attachment Methods
  • Tolerance Considerations
  • Product Finishing
  • Q&A

Stay tuned for future technical plastic thermoforming webinars from Productive Plastics

Thermoforming for Multi-Part Assembly – Live Webinar with McConnell Co.

Thursday, November 17, 2022
Categories: Plastic Thermoforming Event Hosted by Productive Plastics, Technical Thermoforming Webinar, Thermoforming

At Productive Plastics, many of the thermoformed plastic parts that we manufacture for our customers are not stand-alone pieces, but components of an assembly or multi-part enclosure.  Like a puzzle, these individual parts must be manufactured to fit together with precision and uniformity to successfully create the finished product.

Productive hosted a live webinar on December 6th, 2022, with renown thermoforming expert Robert Browning of the McConnell Company discussing considerations for designing and manufacturing a multi-part assembly with plastic thermoformed parts.

  Some of the topics we covered:

  • Vacuum vs Pressure Forming
  • Material Considerations
  • Application to match process
  • Attachment Methods
  • Tolerance Considerations
  • Product Finishing
  • Q&A

Update* see a recording of this webinar at the link below:

Thermoforming for Multi-Part Assemblies Replay

Understanding Heavy vs thin gauge plastic thermoforming

Sunday, April 07, 2019
Categories: Thermoforming

While the difference in starting thickness between heavy gauge thermoforming (sometimes referred to as thick gauge or sheet fed thermoforming ) and thin gauge (also referred to as roll-fed) thermoforming may only begin as a few tenths of an inch in part thickness, the two are utilized in different applications than one another as the manufacturing techniques, machinery required, and project scope differ.

The machinery required is unique for each process category, meaning most plastic thermoforming manufacturers specialize in only one or the other. For instance, Productive Plastics is a custom heavy gauge plastic thermoforming manufacturer. So, you can save some time when searching for a processor if you know which category of thermoforming is the right solution for your application.

Here are the essential differences between heavy and thin gauge plastic thermoforming:

Plastic Thermoforming Heavy Gauge Thin Gauge
Manufactured Part Thickness (approximate) .060 -.375″ 1.5 – 9.5 mm < .125” < 3mm
Machinery Type Sheet Fed Roll Fed
Thermoplastic Materials Used (Most Common) ABS
Polycarbonate
HDPE
Polypropylene (many material variants available) 		PETG
PET
Clear PVC
Styrene
Polypropylene  
Annual Volume Low – Mid Volume < 10,000 High Volume > 10,000
Typical Applications -Medical device enclosures
-Transportation interior parts (window masks, wall and ceiling panels, seating, luggage racks)
-Kiosk enclosures
-Industrial equipment covers
-Electronic equipment enclosures 		-Clamshell packaging
-Food service packaging
-Disposable cups, plates, and trays
-Food containers
-Small medical device packaging
Heavy Gauge – Medical Device Enclosure
Thin Gauge – Food Packaging

Does your application favor heavy gauge thermoforming? If so, contact us or download our Heavy Gauge Plastic Thermoforming Design Guide for more detailed information on the features and benefits of plastic thermoforming and to explore how Productive Plastics can provide manufacturing solutions for your product.

Please contact Productive Plastics for more information on the thermoforming process
Please download the heavy gauge thermoforming design guide from Productive Plastics

Plastic Thermoforming, Pressure Forming, and Vacuum Forming – What’s the Difference?

Friday, October 12, 2018
Categories: Technical, Thermoforming, Thermoforming Material

The terms “plastic thermoforming”, “pressure  forming”, and “vacuum forming” are all used to describe plastic forming processes. While similar, there are subtle and important differences in these terms and processes that may not be well known outside of the plastic manufacturing industry.

Here is a brief breakdown to get you talking thermoforming like a pro in less than a minute:

Plastic Thermoforming is the generic broad label given to the plastic manufacturing process that heats thermoplastic sheet material (thermo) and then applies pressure or vacuum to form into a 3-dimensional shape (forming).

Pressure and Vacuum Forming are the 2 most common plastic thermoforming manufacturing techniques, under the umbrella of plastic thermoforming. They differ primarily in the method of applying pressure/vacuum to transform the heated plastic sheet into the desired 3-dimensional shape.

Pressure Forming Process

Pressure Forming Process

Vacuum Forming Process

Vacuum Forming Process
 

Plastic Thermoforming

 

Pressure Forming

Vacuum Forming

 Pressure Forming IllustrationVacuum forming Illustration
Process DescriptionSheet thermoplastic material is heated until pliable. Positive pressure is then applied above the heated sheet, pressing the material into the surface of a mold to create the desired 3-dimensional part shape.

 

Full Disclosure – The air under the sheet is also evacuated to assist in stretching the material over the mold, but the positive pressure applied is up to 5x greater.

Sheet thermoplastic material is heated until pliable and placed over a mold. The air is then evacuated between the heated sheet and mold creating a vacuum that pulls the material onto the surface of the mold to create the desired 3-dimensional part shape.

 

 

Watch a 1-minute video of a part being vacuum formed.

Key Benefits
  • Aesthetic surface finishes (texture, branding, in mold design)
  • Often eliminates need for post-production painting
  • High level of detail (rivals injection molding)
  • Tighter radius formation
  • Greater undercut depth and definition
  • In mold vents, louver, and attachment point geometry
  • Larger part capability
  • Faster cycle times
  • Lower tooling costs
ToolingNegative  toolingPositive  tooling (typically)
 

 

Primary Part Surface (Dimensional & Aesthetic)

 

 

 

Outside (part surface contacting the tool)

 

 

Inside (part surface contacting the tool)

Application Examples
  • Device Enclosures (medical, dental, kiosk, electrical, etc.)
  • Transportation (air, mass transit, rail) interior components (seating, window masks, wall and ceiling paneling, etc)
  • Material handling equipment interior components
  • Recreation and utility vehicle components
  • Food service components
  • Handling trays and dunnage
  • Pick up truck bedliners
  • Waste water management components
  • Portable toilet components
  • Large equipment enclosures
  • Agricultural related equipment and components

In addition to pressure forming and vacuum forming, there are other methods, such as twin sheet thermoforming (to be covered in a future post), that give plastic thermoforming a vast portfolio of manufacturing capabilities that offer product solutions to a wide range of industries and applications. Plastic thermoforming often outperforms other processes and materials such as fiberglass (FRP) , metal, or injection molding.

Want to learn more about which plastic thermoforming process is the right solution for your project?

Please contact us.

Please contact Productive Plastics for more information on the thermoforming process
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Looking for more technical information?

Download the Thermoforming Design Guide, Process Comparisons, Conversion Guides, and other useful thermoforming information from our technical resource library.

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Ready to explore how Productive Plastics can add to the success of your project?
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