Thermoforming thrives in niche and mid-volume markets that need large parts, low tooling costs, low production volumes, fast turnaround, and lightweight parts.
September 4, 2025
From simple to complex shapes
Industrial thermoforming is a widely used manufacturing process that involves heating a plastic sheet until it’s pliable, then forming it over a mold and trimming it into a usable product. Common to the automotive and aerospace sectors for interiors, it offers an excellent means for producing a large variety of parts quickly and efficiently.
Our thermoforming machines incorporate decades of hands-on experience and know-how covering everything from simple plastic parts to highly complex shapes with consistency and reliability.
Vacuum forming
Heats and forms a single sheet of thermoplastic material, obtaining the final shape by using a vacuum applied to the mold
Twin sheet
Heats 2 sheets, using air injection and a vacuum to create hollow structural parts in a single step
Thermocovering
Creates aesthetic parts by vacuum forming thermoplastic layer to structural inserts
Pressure forming
Uses extra hydrostatic pressure with a vacuum to create more complex shapes for high-end applications
Thermocompression
Uses dual action forming to get the most out of lightweight thermoplastic-based composites
Thermoforming strengths
- Aesthetic: high quality surfaces, large freedom of colors and appearances at affordable costs
- Design flexibility: easy to make large, thin-walled parts with smooth finishes
- Material efficiency: thin plastic sheets can be optimized for performance and cost
- Scalability: fits any production scale
- Sustainability: by definition uses thermoplastic materials that are recyclable and biodegradable
Thermoforming thrives in niche and mid-volume markets that need large parts, low tooling costs, low production volumes, fast turnaround, and lightweight parts. For highly complex parts it is unlikely to replace injection molding despite the high cost difference in tooling, but it remains a viable and often superior choice for many commercial and industrial applications.
Thermoforming vs. comparable technologies
| Process | Thermoforming | Injection Molding | Blow Molding |
|---|---|---|---|
| Tooling cost | Very low | High | Medium |
| Volume | Low-medium | High | Medium-high |
| Part complexity | Low-moderate | High | Low-moderate |
| Cycle time | Medium-Slow | Fast | Fast |
| Surface finish | Excellent | Very good | Moderate |
| Pressure required | Very low | High | Moderate |
| Overall suitability | Low-medium volume, simple parts | Mass production, complex parts | Hollow parts, bottles, containers |
Are you looking for a tailored solution?
Contact us today to discuss your specific needs and find out how our custom solutions can enhance your production process. Don’t wait — let’s create excellence together!
