Shaped
Before
You Asked.
Vacuum and pressure thermoforming for medical device trays, automotive interior panels, and FDA-compliant food clamshells — from CAD to first article in 14 days.
US Former
14 Days.
CAD to Approval.
From the moment your file lands in our engineering queue to the day a first-article part is in your hands — every step is scheduled, documented, and accountable.
CAD Receipt & DFM Review
Your STEP or IGES file is reviewed by our tooling engineers for draft angles, wall thickness, and draw ratio. A manufacturability report is returned within 4 hours.
.STEP / .IGES / .DXF acceptedAluminum Tool Machining
Single-cavity or multi-cavity prototype tool is CNC-machined from 6061 aluminum. High-gloss A1 diamond polish for medical and optical-clarity parts.
6061 Al · A1 polish availableMaterial Staging & Trial Runs
Sheet stock is cut to gauge — PETG, ABS, HIPS, or HDPE — and trial pulls are run to dial in temperature, vacuum, and cycle time before first article.
Gauge: 0.030″ – 0.250″First Article Inspection
One production-representative part is CMM-measured against your drawing. A final part drawing reflecting actual tolerances is issued alongside a process capabilities report.
CMM report includedClient Approval & Production Release
First article is shipped for your incoming inspection. On approval, the tool is released for production. Minor dimensional changes are incorporated at no tooling charge.
No-charge minor revisionsLead Time vs. Alternatives
| Process | Prototype Lead | Production Tooling | Tooling Cost |
|---|---|---|---|
| Thermoforming (Formline) | 14 days | 6–8 wks | $1,200–$8,000 |
| Injection Molding | 8–12 wks | 12–16 wks | $15,000–$80,000 |
| CNC Machining | 3–5 days | Not scalable | $0 (per part) |
±0.010″
On Every Run.
Pressure forming applies up to 100 psi against your aluminum tool, capturing textures, undercuts, and dimensional tolerances that vacuum forming alone cannot achieve. Every production run ships with a full process capabilities report.
Process Comparison Matrix
| Attribute | Thermoforming | Injection Molding | CNC Machining |
|---|---|---|---|
| Linear Tolerance | ±0.010″ | ±0.005″ | ±0.002″ |
| Wall Thickness Variation | ±10% | ±5% | N/A |
| Prototype Tooling Lead | 14 daysBest | 8–12 wks | 3–5 days |
| Tooling Cost (Prototype) | $1.2k–$8k | $15k–$80k | $0 |
| Surface Detail (Texture) | High (pressure) | Very High | Machined |
| Part Weight vs Steel | −60–80% | −60–80% | −30–50% |
| Large Part Capability | 5′ × 9′ sheetsBest | Limited | Limited |
| Min Wall Thickness | 0.030″ (medical)Best | 0.040″ | 0.060″ |
Pressure Forming
Unlocks Detail
Pressure forming introduces an additional step of applying high pressure to the heated sheet, enhancing detail and definition when conforming to the mold — achieving injection-molding-level surface quality at thermoforming tooling costs.
2.4M Parts.
Every Month.
Five presses running three shifts on a 5-day week. Thin-gauge medical to heavy-gauge automotive — simultaneous tooling slots mean your program doesn't wait for another customer's run to finish.
Press Fleet
Press 1–2
Press 3–4
Press 5
Materials We Run
Polyethylene Terephthalate Glycol
Medical trays, food clamshells, electronics
Acrylonitrile Butadiene Styrene
Automotive panels, industrial housings
High-Density Polyethylene
Chemical containers, outdoor enclosures
High-Impact Polystyrene
Retail packaging, point-of-sale displays
Polycarbonate
Optical-clarity covers, aerospace glazing
Amorphous PET
Beverage packaging, blister cards
Certifications & Compliance
Quality Management System
All production
Medical Device QMS
Medical lines
Food Contact Compliance
Food-grade PETG/HDPE
Cleanroom Capability
Medical sterile packaging
Materials &
Tolerance Guide
32 pages covering every material we run — forming temperature windows, gauge recommendations, FDA/ISO compliance status, and tolerance benchmarks by process. Built for engineers who need proof before an RFQ.
- →8 materials with full property tables
- →Tolerance benchmarks by forming method
- →Medical & food compliance reference
- →Tooling cost estimator worksheet
Download Free Guide
One field. No sales calls unless you ask.