Why ThermoFab?

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Sometimes you just have to say: WTF?


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Custom Plastic Enclosures.

Revolutionary Process.


It's not the #WTF? you are
    thinking of -- THINK
    Why ThermoFab.


Why ThermoFab You Ask?  

1.  True manufacturing partner.

2.  Plastics thermoforming expert.

3.  Gets your product to market without headaches.



In this fast paced world of instantaneous everything - from tweets to hash tags to up to the millisecond news:  


Our #1 priority is our happy clients and their custom plastic enclosure projects.  We are
ready to assist you with your thermoforming project.  Contact us by
emailing design@thermofab.com   

-We focus on:  Custom Plastic Enclosures and
    our revolutionary process using our lean manufacturing approach. 

Contact ThermoFab by emailing us at design@thermofab.com or by calling 978-425-2311.      

ThermoFab can assist with engineering and any design for manufacturability challenges you face.   We offer the fastest time to market design to manufacturing options.                                            



Thermoforming Up Tick: Second Quarter Project Releases

Second Quarter Push: Up-tick in Project Releases 

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Protective Water Resistant Custom Plastic Enclosure

The 2nd quarter push is upon you.  Project releases have hit an up-tick. 

Contact ThermoFab by emailing us at design@thermofab.com or by calling 978-425-2311.   

ThermoFab can assist with engineering and any design for manufacturability challenges you face. 

We offer the fastest time to market design to manufacturing options.  

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Custom Military Project Assembly


If your engineering department is swamped: The ThermoFab design and engineering experts will help you attain your project manager's timeline goals for project release. 


If you already have a design, we will update your 3D model files or if you need a designer we can create an eFile or hand drawn industrial design rendering of your part. 




We've collaborated with our visually oriented clients to created renderings and e-files from everything you could imagine, including sketches on cocktail napkins all the way to more sophisticated CAD files.


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Custom Military Enclosure



Memorial Day: A tribute to all fallen soldiers who have sacrificed for our freedom.


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Headquartered in Shirley, Massachusetts: ThermoFab's manufacturing facilities provide one stop shop for design, engineering, tooling and custom manufacturing.  With 37 years of thermoforming experience, ThermoFab is well known for our Design, Develop, Deliver Services. 

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Please contact ThermoFab today at 888-494-9777 or  978-425-2311 for assistance with your custom heavy gauge thermoforming project.




Thermoforming: How to create a Star Tradeshow Product?


 Will Your Tradeshow Product be a Superstar or a Fright?

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To Market, To Market--Think Toward The Future
Don't think "cost savings" when attending a tradeshow. Take the time to perfect the design as much as possible. Why? Simple. The more accurate the design, the easier it will be to modify it after receiving feedback at the tradeshows. Putting the time and effort in up front will make for smoother and faster transitions from CAD-to finished parts. With a company like ThermoFab, you can go from completed design to finished parts in just 4-6 weeks.

Think "Touchy Feely"
Appealing to the senses is important from a marketing standpoint (did you hear about the billboard for chocolate chip cookies that gave off the scent of cookies baking?). Vibrant colors appeal to the eyes, sleek edges appeal to our sense of touch, and even the smell of a freshly thermoformed part adds a certain allure.

Bottom line?

Your prospects need to see and touch a real product--one that can withstand bending and prodding and holding. Because of this, avoid stereolithography (SLA). But why, you might ask, considering SLA models can be created from CAD files in a matter of hours? Sure, you might have a "real" three-dimensional object in hand, but problems with SLA models exist. They're costly (the liquid photopolymer used in the SLA machine can cost upwards of $800/gallon), and the process (which involves the layering of the liquid photopolymer) is not always structurally sound. Imagine having an SLA model at a tradeshow and it doesn't bend or flex the way it's supposed to or worse--it breaks in a prospective customer's hands. Wouldn't it be better to have the actual part instead of a raw piece? Even if you attend a tradeshow with a prototype, it should be made from materials similar to those that will be used in the final product, and it should have a production finish.

Show and Sell
It might be easy to rationalize that tradeshow product displays aren't that important in the grand scheme of things. After all, the people looking at these products realize these items are just examples, right, not fully rendered parts?

Well, not so fast. Think about it. In today's hectic world and crowded marketplace, a person has only so many chances to engage a prospective customer. The beauty of tradeshows is that they're filled with captive audiences. People attend for a reason, such as a vested interest in a particular industry. Many of these people are looking for products--perhaps products like yours. Where else besides a brick and mortar storefront will you have the opportunity to speak with a hot prospect face-to-face while showing your wares? When you look at it like this, suddenly those products displayed at tradeshow booths take on new meaning. This is your opportunity to show and sell. Don't skimp.



Summer Fun and Thermoforming Resources!

Ahhh Yes - Summer and The Email Inbox

We know how it goes: emails overwhelm your inbox and the next thing you know, you're deleting at will. Problem is, you know you might be missing some good stuff! That's the purpose - and only purpose - of this blog entry...to provide you with links to some of the resources that you might have missed. We want to arm you with benchmarks you should use when evaluating companies like ThermoFab so that you can select the best company to manufacture your product:


And please know that we'd love the opportunity to "wow" you with our thermoforming process. Contact us today to schedule a call to discuss your product's needs, or, better yet, set up a time to tour our plant. Telephone Lisa King or Michael Wahl at 888-494-9777.  We truly enjoy showing clients and prospective clients around our Massachusetts office and manufacturing facility.


ThermoFab Thermoforming Design: It's in the Details

Design - Details, Details, Details

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Details, Details, Details
Design Services Designed Around Your Needs
Details - Interior Large Custom Plastic Thermoformed Enclosure
Design Services which concentrate on the details of your custom plastic enclosures. We're excited to announce an increased investment in ThermoFab's in-house design services. This investment will further ensure that our customers continue to receive the highest quality parts from a company that truly is a one-stop shop in the engineering, design, and manufacturing of thermoformed plastic enclosures.

Whether you already have a designer or a design or you need a designer to turn that concept into reality, ThermoFab can help in both scenarios.

If you already have a designer or a design, we'd be happy to do the following:

  • Review your existing plastic design files.
  • If we decide that we can manufacture your product to our exceptionally high quality standards, we'll move your files into the design assessment stage.
  • From there, we'll get your design files ready for our expert engineering and plastics manufacturing.

If you need a designer, we'd be happy to do the following:

  • Discuss the idea you have in mind and determine if we're the right fit for engineering and manufacturing your part.
  • Create a rendering and e-file of your part (we've created renderings and e-files from everything you could imagine, including sketches on cocktail napkins all the way to more sophisticated CAD files).

We invite you to read about some of the design and manufacturing challenges we've solved for our customers.


Design: It's in the Details

DSC01124 resized 600DSC01127 resized 600Sometimes what is hidden behind a product - it's interior details - are the most crucial in the design process! These interior photos from a medical device highlight sophisticated attachment details and intricate design. Contact us today to learn more about our Custom Plastic Enclosures and Revolutionary Processes

Justifying the Jump from Metal to Plastic

Justifying the Jump from Metal to Plastic

We all know that the eye gravitates toward curves versus boring straight lines! If money was no object - would you choose a Corvette or a Pinto? The challenge faced today by most product managers and designers is bringing a product to market within budget and justifying the external enclosure as 'curvy and swerve"y" ' vs. a ho-hum metal box. Some distinct projects come to mind where redesigns and upgrades have paid off for our clients!

When should a company consider making the Jump
to Plastic?

Redesigns from metal housings to plastic are easily justified by marketing and engineering teams. Curves along with creating a signature shape or look brand the product line and create buzz in the marketplace. Simply put: Buzz sells more product!

Is it more expensive to produce something in plastic or metal?
Short answer - yes! (If we are talking about easily bent sheet metal.) There are two choices - create curves with a tooling investment or keep the design angular and most likely boring with a basic sheet metal shape. An investment is needed - but with discussion and want lists - an upgraded look is easily achievable within budget!

If the company decides to make the jump, what costs will the company need to consider (design, materials, etc.?)
Companies have to consider their user, their market when working the budgets to analyze the overall cost of the enclosure. If you spend 10%-20% of the total product cost on the exterior enclosure - - the so-called first impression "view" will you sell 100% more product? Yes - we've seen product redesigns and branding efforts pay off immediately for clients. The ROI is amazing to witness!

When is it not a good idea to manufacture in metal?

  • The product enclosure is an essential aesthetic design element.
  • When the product design in metal is too complicated for the metal house to manufacture and drives cost.
  • An angular simple box design makes the enclosure look flimsy and doesn't promote the sophisticated product line.

Did you find this information helpful? Great! You should download our free Design Guide, because these are the sort of quality tips and explanations we provide.

7 Considerations When Choosing a Thermoforming Company


Picture this scenario: you and your company have been laboring over a new product concept. You've done the market research, and you know demand exists. You've designed the product, and you've collaborated with a thermoforming company to manufacture the plastic enclosure. You've priced the product to sell right out of the gate. You've created buzz, and you've worked tirelessly on the marketing plan, the social media plan, and the PR plan. All you're waiting for now are the actual thermoformed parts.

You wait. And you wait, only to find out there's an issue with the design. And then the materials. And-oh wait-the company that's manufacturing the parts is behind schedule. There's nothing you can do (well, unless you want to sink more money into starting all over with another manufacturer).


While this might seem like an extreme example, it's not. Your time to market (TTM) is determined by the length of each stage of a product's development, one of the most crucial of which is the actual manufacturing of your thermoformed parts.

This is why it's important to keep in mind that not all thermoforming companies are alike. You must select carefully. At the same time, choosing a thermoformer doesn't need to be a stressful process, if you know what to look for-and what to avoid. And that's where this white paper comes in.

We've outlined the key questions to ask and factors to consider when making your decision. Your product is an investment. Take the time to speak to several thermoformers to understand how each one approaches the manufacturing process.


Here's something to note before you continue reading:

Understanding the difference between thin- and heavy-gauge thermoforming is essential when researching a thermoforming company's expertise. Knowing up front what type of thermoforming you need will help save you time during the initial contact phase.

There's no sense in contacting a heavy-gauge thermoformer when what you need is a thin gauge one. Most packaging-think of the plastic that holds a wireless headset-is thin-gauge thermoforming. Heavy-gauge thermoforming involves a plastic part that in essence "becomes" the product. For example, think of your computer or a medical device at the hospital. The plastic enclosure not only covers and protects the delicate electrical components on the inside, but also makes the product look better.

While you can use most of the considerations that we discuss below for evaluating either thin- or heavy-gauge thermoforming companies, it's important to know that this paper was written with heavy-gauge thermoforming in mind.

Below is the link to our whitepaper: