ThermoFab specializes in thermoforming heavy-gauge plastic enclosures, customized to meet your project’s specifications.


At ThermoFab, our expertise in thermoforming equips us to expertly manage and manufacture projects of various sizes and complexities. Our extensive experience spans a range of diverse industries such as medical devices, automation & robotics, defense & security, and test & measurement. Whether it’s thermoforming heavy-gauge plastic equipment housings, shrouds, covers, bases, or intricate component parts, we offer solutions to match your application requirements.

What sets us apart in the realm of thermoforming is our unwavering commitment to precision, quality, and customer satisfaction. From initial design consultations to full production runs, to our quality management practices, we provide invaluable insights and support at every stage of production.

Check out our case studies for more information

Thermoformed part sample
Thermoforming Advantages


Thermoforming provides several benefits, making it a preferred choice for manufacturers looking to produce a wide range of products.

  • Cost-effectiveness: tooling costs are typically lower than other molding techniques
  • Versatility: beneficial for small to medium production runs with varying requirements (low hundreds annually)
  • Rapid Prototyping: minimal set-up costs & quick turn-around times allow the creation of quick prototypes before committing to full production runs
  • Flexibility: ability to choose from a diverse range of materials to suit your production needs
  • Customization: plastic thermoformed parts can be easily customized to incorporate branding elements using painting, silk screening or pad printing

size capabilities

With our cutting-edge manufacturing capabilities, we’re equipped to produce components of various sizes. Whether you require intricate designs or larger-scale productions, we can accommodate your needs with precision and efficiency. Additionally, our expertise extends to achieving a wide range of part wall thicknesses, ensuring optimal performance for your applications.

  • Can manufacture components up to to 1.5m (60”) x 2.4m (96”) x .3m (11”)
  • Part wall thickness from .04” to .38” (1 mm to 10 mm)
thermoforming and injection molding production process

materials of construction

If you need assistance, we can help with material selection from our comprehensive list of typical engineering plastics below. If you would like to request custom or additional materials, we are happy to discuss those options with you.

  • Starex Flame-retardant ABS
  • Kydex Acrylic/PVC
  • Sabic Polycarbonate ABS blends
  • Polycarbonate
  • ABS
  • PVC
  • Acrylics
  • High impact polystyrene (HIPS)
  • Polypropylene
  • HDPE