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Thermoforming at RapidMade

Thermoforming is a fast and inexpensive technology for manufacturing durable products by shaping hot thermoplastic sheets around a mold.

It requires less lead time and tooling costs than traditional manufacturing techniques like injection molding or machining while also offering a lower part cost than 3D printing. Although thermoforming has more design limitations than these technologies, it offers excellent value for compatible projects.

With bed sizes up to 4’ x 4’, our thermoforming services are ideal for a range of products, from custom trays and packaging to large panels, displays and housings.

Thermoform styrene tray gif

Get a Customized Quote in 24 Hours or Less

Request a quote with our Quick Quote tool or by giving us a call. A RapidMade engineer will review your design and send you a price in 24 hours or less. Thermoformed products typically ship in 2-4 weeks.


Durable Thermoplastics

Real thermoplastics are strong, durable and inexpensive compared to 3D printed materials. RapidMade offers an extensive range of plastics for thermoforming, such as PETG, HIPS, ABS, Styrene, PC, Acrylic and many more, in thicknesses ranging from 0.020" to 0.250" (0.5 mm to .6.5 mm).

With so many options, thermoformed products are able to meet a host of mechanical and aesthetic demands, from conductivity and heat resistance to FDA food grade certifications.

 Custom thermoformed panel for an underwater camera housing.

Custom thermoformed panel for an underwater camera housing.


Thermoforming and Rapid Tooling: Better Together

Using inexpensive rapid manufacturing techniques like 3D printing, milling and casting, RapidMade can create tooling for thermoforming in under 48 hours.

Not only does this allow us to produce parts faster, it also makes it easy to prototype your product. Once prototypes are made, adjustments are cheap compared to traditional technologies like injection molding. Click here to find out more!

 Short-run urethane mold for a thermoformed automotive testing tool.

Short-run urethane mold for a thermoformed automotive testing tool.


 Custom tray for use with collaborative robotics.

Custom tray for use with collaborative robotics.

Improve Efficiency with Custom Trays

Custom trays can benefit a range of mprofessional environments, from automated assembly lines to hospital operating rooms. By tailoring solutions to your specific needs, RapidMade can create tools that fit seamlessly into your existing production.

 Clamshell packaging formed on tooling made in under 24 hours.

Clamshell packaging formed on tooling made in under 24 hours.

Packaging Made Easy

Good packaging provides two major benefits: protecting your products on their way to your customers and creating a good impression once they get there. With precise tolerances and a variety of presentation options, thermoformed packaging excels at both!

 3D branding demonstration which combines thermoforming with plastic imaging.

3D branding demonstration which combines thermoforming with plastic imaging.

3D Plastic Imaging

RapidMade can quickly create inexpensive custom branding or visual textures for signs, packaging, retail displays and more by printing high-resolution 2D images onto sheet plastic and creating calibrated 3D tooling to match.


How Does Thermoforming Work?

First, a plastic sheet is heated until pliable. It is then pressed over a mold. In the case of vacuum forming, a vacuum is used to pull the plastic tightly against the mold, ensuring consistent definition in the final product. Once the product is taken off the mold, the excess plastic is trimmed off and recycled.