Custom Precision Thermoforming Parts

At Fecision, we combine advanced thermoforming technology with decades of manufacturing expertise to deliver custom plastic parts that meet your exact specifications.

Whether you need prototypes, low-volume production, or high-volume manufacturing, our thermoforming services provide the perfect balance of quality, cost-effectiveness, and design flexibility.

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ISO 9001: 2015 Certified Processes

ISO 13485: 2016 Medical Device

IATF 16949: 2016 Automotive AS9100 Quality Managment

Faster Lead Time for Production Needs

In-Process Inspection with CMM

Thermoforming Services: Custom Plastic Solutions

Thermoforming is a manufacturing process where thermoplastic sheets are heated to a pliable state, stretched over a mold, and trimmed to create a finished product. This method is widely used for producing lightweight, durable, and cost-effective parts. Common applications include packaging (e.g., food containers), automotive components, refrigerator liners, and medical device housings.

Unlike injection molding, thermoforming works with pre-made plastic sheets rather than raw plastic pellets. This fundamental difference makes thermoforming ideal for creating larger parts, achieving faster production cycles for prototypes, and providing more economical tooling options for many applications. The process is highly adaptable, accommodating various plastic materials and design requirements across industries.

Popular Features

Cost Efficiency

Lower mold costs compared to injection molding, ideal for short to medium production runs.

Design Flexibility

Accommodates complex geometries and large part sizes.

Material Versatility

Compatible with a wide range of thermoplastics.

Vacuum Forming

Uses vacuum pressure to pull heated plastic against a mold. . Perfect for packaging, displays, and basic enclosures.

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Pressure Forming

Combines vacuum and compressed air for higher detail and surface finish (e.g., medical trays).

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Twin Sheet Forming

Forms two sheets simultaneously and fuses them together, creating hollow, double-walled structures.

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Mechanical Forming

Employs mechanical force for deep-draw parts (e.g., refrigerator liners).

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Drape Forming

Sheets are draped over a mold without vacuum, suitable for shallow shapes.

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Billow Forming

The heated plastic sheet is first pre-stretched using air pressure before being shaped.

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Our engineering team will recommend the optimal thermoforming technique based on your part requirements, production volume, and budget considerations.

We can also combine different methods to achieve the best results for complex projects.

Standard	Technical Data
Sheet Thickness	0.25 mm – 12 mm (0.010 in – 0.500 in) depending on material
Part Size	Small components up to large panels >2 m (80 in) in length
Draw Depth	Typically up to 75% of sheet width; varies with material and tooling
Tooling	Aluminum, steel, or composite molds depending on production volume
General Dimensional Tolerance	±0.5 mm to ±1.0 mm per 25 mm (±0.020 in to ±0.040 in per inch)
Trimmed Dimensions	±0.25 mm to ±0.75 mm (±0.010 in to ±0.030 in) depending on trimming method
Wall Thickness Variation	±10–20% (due to material stretch during forming)
Flatness	±0.5 mm per 100 mm (±0.020 in per 4 in), depending on material and cooling
Hole Size / Cutouts	±0.25 mm (±0.010 in) achievable with CNC trimming or drilling

Acrylonitrile Butadiene Styrene (ABS)

Acrylonitrile Butadiene Styrene-thermoplastic polymer known for its excellent balance of strength, toughness, and rigidity.

Properties:

①Highly resistant to impact and can withstand physical stress without cracking or breakin

②Capable of withstanding temperatures up to 100°C (212°F) without significant degradation

③Resistant to many acids, alkalis, oils and other chemicall substances

④Smooth, glossy surface to be easily painted or coated

⑤Easy to mold and can be processed through a variety of methods

Application:

① Automotive: Interior panels, dashboards, trims, protective covers
② Consumer Goods: Appliance housings, storage containers, display panels
③ Electrical & Electronics: Switch covers, instrument panels, protective enclosures

Glycol-Modified PET (PETG)

Glycol-Modified PET is a thermoplastic polyester resin. It is produced by modifying the traditional PET through the addition of glycols. This modification alters the molecular structure of PET, resulting in a material that combines the basic characteristics of PET with enhanced properties such as improved transparency, flexibility, and impact resistance.

Properties:

①High optical clarity, similar to glass, allowing for clear visibility

②Better impact resistance and more flexible than standard PET

③Good resistance to a variety of chemicals

④Easy to thermoform, mold, and fabricate

⑤Recyclable

Application:

① Consumer Goods: Food packaging, display cases, protective covers
② Medical & Healthcare: Equipment housings, trays, device covers
③ Retail & Electronics: Point-of-sale displays, protective enclosures, product packaging

High-Density Polyethylene (HDPE)

High-Density Polyethylene is a type of polyethylene thermoplastic polymer. It is formed through the polymerization of ethylene under specific conditions, resulting in a highly crystalline structure with a relatively high density.

Properties:

①High tensile strength and impact resistance

②Remarkable resistance to a wide range of chemicals, including acids, alkalis, and many organic solvents

③Good thermal stability within a certain temperature range

④Excellent moisture resistance, preventing water and moisture from penetrating easily

⑤A relatively low friction coefficient, substances can slide over its surface easily

Application:

① Packaging Industry: Containers, caps, trays, crates
② Automotive: Fuel tanks, protective panels, interior liners
③ Consumer Goods: Storage bins, appliance housings, cutting boards

Polycarbonate (PC)

Polycarbonate is a high-performance thermoplastic polymer. It is an amorphous engineering plastic, which is synthesized through the reaction between bisphenol A and phosgene or diphenyl carbonate.

Properties:

①Excellent optical clarity, high light transmittance

②Good dimensional stability, low coefficient of thermal expansion

③Withstand significant impacts without breaking or cracking

Application:

① Electrical & Electronics: Switch covers, instrument panels, protective enclosures
② Automotive: Headlamp lenses, interior panels, sunroof components
③ Consumer Goods: Transparent housings, display cases, protective shields

Polyvinyl Chloride (PVC)

Polyvinyl chloride is a versatile thermoplastic that can be formulated as rigid or flexible. It has excellent flame resistance and can be used in a variety of applications.

Properties:

①Rigid PVC is strong, durable, and has good chemical resistance.

②Flexible PVC contains plasticizers to make it more elastic.

Application:

① Construction & Building: Wall panels, ceiling tiles, window profiles
② Electrical & Electronics: Cable insulation, switchgear covers, housings
③ Consumer Goods: Signage, packaging trays, appliance panels

Polypropylene (PP)

Polypropylene is a semi-crystalline thermoplastic with good mechanical properties, including high tensile strength, stiffness, and impact resistance.

Properties:

①A relatively high melting point gives it good heat resistance

②Resistant to chemicals

③Excellent fatigue resistance

Application:

① Packaging Industry: Food containers, trays, disposable cups
② Automotive: Interior panels, protective covers, storage compartments
③ Consumer Goods: Storage bins, appliance housings, household items

Polystyrene (PS)

Polystyrene is a transparent, brittle thermoplastic with good dimensional stability and low cost. There are two main types: general-purpose polystyrene (GPPS) and high-impact polystyrene (HIPS). HIPS has improved impact resistance compared to GPPS.

Properties:

①Excellent optical properties, suitable for applications where clarity is important.

②It can be either clear or opaque and is relatively low-cost.

③Rigid and easy to process, with good dimensional stability.

Application:

① Packaging Industry: Food trays, clamshell packaging, disposable containers
② Consumer Goods: Display cases, signage, storage boxes
③ Medical & Healthcare: Test tube racks, specimen trays

Polyethylene (PE)

Polyethylene is a thermoplastic polymer with a wide range of densities, including low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and high-density polyethylene (HDPE).

Properties:

①LDPE is flexible, transparent, and has good chemical resistance.

②LLDPE offers enhanced strength and toughness compared to LDPE.

③HDPE is more rigid, has higher tensile strength, and excellent chemical resistance.

Applications:

① Packaging Industry: Containers, trays, crates
② Automotive: Fuel tanks, protective panels, liners
③ Consumer Goods: Storage bins, appliance housings, cutting boards

Polyethylene Terephthalate (PET)

Polyethylene Terephthalate is a widely-used thermoplastic polymer in the polyester family. It is produced through the polymerization reaction between ethylene glycol and terephthalic acid or dimethyl terephthalate.

Properties:

①Recyclable, can be collected, processed, and recycled into new products

②Highly transparent, offering excellent optical clarity similar to glass

③Outstanding barrier properties. It has low permeability to gases such as oxygen, carbon dioxide, and water vapor

④Good mechanical strength and stiffness, relatively high tensile strength

Application:

① Packaging Industry: Blister packs, food trays, bottles
② Medical & Healthcare: Medical trays, device housings
③ Retail & Electronics: Display cases, protective packaging

Polyphenylene Sulfide (PPS)

Polyphenylene Sulfide is a high-performance engineering thermoplastic polymer. It is composed of repeating phenylene groups connected by sulfur atoms.

Properties:

①Outstanding thermal stability, withstand continuous use at high temperatures

②Excellent resistance to a wide variety of chemicals, including acids, bases, solvents, and fuels

③A very low flammability rating and does not support combustion easily

④High tensile strength, flexural strength, and modulus

⑤High crystallization rate and low coefficient of thermal expansion

⑥A low dielectric constant and high electrical resistivity

Application:

① Electrical & Electronics: Connectors, terminal blocks, insulating components
② Automotive: Pump housings, valve components, under-hood parts
③ Industrial Equipment: Gears, bearings, chemical-resistant machine parts

Thermoplastic Polyurethane (TPU)

Thermoplastic Polyurethane is a type of elastomeric thermoplastic polymer. It is created by reacting diisocyanates with polyols and chain extenders. TPU combines the characteristics of rubber and plastic.

Properties:

①Excellent elasticity, similar to that of rubber

②outstanding abrasion resistance, withstand repeated rubbing, scraping, and friction without significant wear

③Good resistance to a wide range of chemicals, including oils, greases, and many solvents

④excellent impact resistance

⑤Transparency and Colorability

Application:

① Consumer Goods: Protective cases, wearable items, footwear components
② Automotive: Seals, gaskets, interior trims
③ Industrial Equipment: Tubing, flexible protective covers, conveyor parts

Acrylic (PMMA)

Acrylic is a synthetic polymer made from the polymerization of methyl methacrylate monomers. It is a transparent, hard, and lightweight thermoplastic material with a relatively high molecular weight.

Properties:

①Extremely high transparency, with a light transmittance of up to about 92%, which is very close to that of glass.

②Excellent resistance to ultraviolet (UV) light, weathering, and environmental degradation

③High hardness and impact resistance

④Relatively easy to process

⑤Excellent electrical insulation properties

Application:

① Consumer Goods: Display cases, signage, lighting covers
② Automotive: Light lenses, interior trim panels
③ Medical & Healthcare: Equipment covers, protective shields, lab trays

High Impact Polystyrene (HIPS)

High Impact Polystyrene is a thermoplastic polymer material. It is produced by copolymerizing styrene monomers with a small amount of rubber, usually polybutadiene. This unique structure significantly improves the impact resistance of the material compared to general polystyrene, while still retaining many of the basic properties of polystyrene.

Properties:

①Much better impact resistance than ordinary polystyrene.

②Good processability and can be easily formed into various shapes

③Maintain good dimensional stability, with little deformation or shrinkage

④Excellent electrical insulation properties

⑤Good aesthetic properties

Application:

① Packaging Industry: Food trays, clamshell packaging, protective inserts
② Consumer Goods: Appliance housings, display panels, storage containers
③ Medical & Healthcare: Lab trays, test tube racks, disposable equipment

Common Surface Finishes for Thermoforming

Heat Transfer Printing

Transfer patterns, text, etc, to the plastic surface through heat pressing.

Spraying Coating

Spraying or electrostatic coating applies layers (e.g., UV-curable paint, anti-scratch coatings).

Laser Engraving

Laser ablation creates permanent markings (logos, serial numbers) without affecting structural integrity.

Electroplating

Depositing metal layers (e.g., chrome, nickel) onto plastic surfaces via electrolysis.

Chrome Electroplating
Nickel Electroplating

Sandblasting

Compressed air propels abrasive materials like sand or grit at high speed onto an object’s surface, cleaning it, roughening it for better adhesion, or creating a matte finish.

Polishing

Use abrasives, compounds, or buffing tools to refine a surface, reducing roughness, enhancing smoothness

Mechanical Polishing
Chemical Polishing

Need Expert Guidance on Your Thermoforming Project?

Our advanced thermoforming equipment and experienced technicians ensure each step is executed with precision, resulting in high-quality parts that meet your exact specifications.
Our engineering team can help optimize your design for thermoforming and recommend the best materials for your application.

Thermoforming Applications

Industries We Serve

Thermoforming's versatility makes it ideal for a wide range of industries and applications. At Fecision, we've provided custom thermoforming solutions across diverse sectors, delivering components that meet exacting performance and aesthetic requirements.

Medical

Device housings and enclosures
Sterile packaging and trays
Diagnostic equipment components
Patient positioning devices

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Automotive

Interior trim components
Under-hood covers and shields
HVAC ducting and components
Storage compartments and bins

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Packaging

Blister packaging
Clamshell containers
Protective inserts and trays
Food and beverage containers

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Additional industries we serve include agriculture (equipment components, seed trays), retail (displays, signage), consumer goods (appliance parts, product housings), and aerospace (interior components, equipment covers). Our expertise spans from simple packaging solutions to complex technical components with precise specifications.

Cost-Effectiveness

Lower tooling costs compared to injection molding
Economical for both prototyping and production runs
Reduced setup time and faster time-to-market
Minimal material waste through efficient processing

Design Flexibility

Creation of complex shapes and contours
Ability to incorporate undercuts and detailed features
Excellent surface finish and texture options
Rapid prototyping capabilities for design iterations

Production Advantages

Lightweight yet durable end products
Scalable from small batches to high-volume production
Consistent part quality throughout production runs
Quick turnaround times for time-sensitive projects

Draft Angles

Include draft angles of at least 2-3° on all vertical walls to facilitate part removal from the mold. Deeper draws may require increased draft angles of 5° or more for optimal results.

Corner Radii

Avoid sharp corners and edges by incorporating radii of at least 1.5 times the material thickness. This prevents material thinning and stress concentration that could lead to part failure.

Uniform Wall Thickness

Design for consistent material distribution to prevent weak spots.

Undercuts

Minimize or eliminate undercuts when possible, or design for secondary operations.

Texture

Consider how texture placement affects material flow and detail reproduction.

Trim Lines

Design with efficient trimming in mind to reduce secondary operations.

Why Choose Fecision for Custom Thermoforming?

Technical Expertise

Dedicated engineering team with decades of combined experience
Comprehensive design assistance and optimization
Material selection guidance for optimal performance
Process development for challenging applications

Quality Assurance

ISO 9001:2015 certified quality management system
Comprehensive inspection and testing capabilities
Documented quality procedures and traceability
Consistent part-to-part and run-to-run quality

Production Capabilities

State-of-the-art thermoforming equipment
Multiple forming technologies under one roof
Scalable capacity from prototypes to high volume
Secondary operations and value-added services

Customer Service

Dedicated project management team
Transparent communication throughout your project
Flexible scheduling to meet your timeline
Long-term partnership approach

How to Work with Us

The plastic molding process involves numerous parameters that must be carefully regulated to maintain the quality and consistency of the produced components.

Submit Drawings

For a free quote, please submit a product description along with a technical drawing. We also offer reverse engineering services to assist you.

DFM & Quotation

We will provide a DFM (Design for Manufacturability) report or mold flow analysis report. Please be aware that further discussions may be needed during the process.

Mold Manufacturing

Upon your confirmation to the mold design, our team will begin making mold components, which will then be sent for inspection and assembly.

Custom Thermoforming

Once the mold is complete, we will initiate the plastic molding process. A T1 sample will be provided for you to check whether the product details align with your specifications. After approval we will continue massive production.