A decades-old process that’s still shaping the future—literally.
If you’ve ever wondered how custom plastic parts are made quickly and affordably without sacrificing quality, chances are thermoforming had something to do with it. While it may not be the flashiest process on the shop floor, thermoforming continues to be a go-to solution for businesses across automotive, medical, industrial, and retail industries.
But what exactly is it, and why does it still matter in a world of 3D printing and rapid prototyping?
What Is Thermoforming?
Thermoforming is the process of heating a sheet of plastic until it’s pliable, then shaping it over a mold using vacuum pressure or mechanical force. Once the plastic cools and hardens, you’re left with a durable, lightweight part—ready for trimming, finishing, and application. It’s simple in concept but incredibly efficient in practice.
Why Thermoforming Still Matters in Modern Manufacturing
One of the biggest reasons thermoforming remains relevant is scalability. While 3D printing is great for prototypes and low-volume runs, thermoforming is better suited for mid to high-volume production, especially when part consistency and material strength are non-negotiables.
Here’s what sets it apart:
Fast production times
Lower per-unit costs for larger runs
Wide material compatibility (ABS, PETG, polycarbonate, and more)
Excellent strength-to-weight ratios
The Market Speaks: Thermoforming Isn’t Slowing Down
According to Grand View Research, the global thermoformed plastics market is expected to reach $52.5 billion by 2030. Demand from automotive, industrial, and packaging sectors is driving innovation in tooling, design, and sustainability—keeping thermoforming relevant and evolving.
Looking to Scale Smarter? We Can Help.
Whether you’re prototyping a new product or scaling up for high-volume production, our team knows how to put thermoforming to work for you. Explore our capabilities in vacuum forming, check out our custom fabrication solutions, learn how we use CNC tooling and design to support precision forming, or contact us directly to get started with your project today.