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Thermoformed Plastic Products

At Sonolite Plastics Corporation, we manufacture various thermoplastics in sheets to our customer’s exacting specifications. From working with your engineers and product development people to designing your custom mold to manufacturing and finishing, we will support and guide your efforts. In many cases, our people offer solutions that can lead to other manufacturing processes or budget-aware design changes.

What is Thermoforming?

Thermoforming uses thermoplastic sheets or rolls. At its most basic level, the thermoplastic is heated and then, using molds, the plastic is shaped to the customer’s specifications. Plastic components needing wall thicknesses of less than 1.5 mm (0.060 inches) typically are pressed in roll-fed machines while components needing tolerances of more than 3 mm (0.120 inches) are primarily sheet-fed. The machines, or presses, hold the hot plastic sheet to the mold with extreme amounts of vacuum suction or downward pressure in the case of multiple-piece molds.

Materials Use In Thermoforming Plastics

  • ABS
  • Acrylic
  • Celluloid
  • EVA
  • EXS
  • Liquid Crystal Polymer
  • Polymide
  • PET
  • Polyester
  • Polyethylene
  • Polystyrene
  • PVC

Thermoforming Plastic Process

The process of creating your thermoformed plastic components may include the following:

  • Idea Generation
  • Process Analysis
  • Computer-Aided Design
  • Proto-typing
  • Budget Development
  • Inventory Warehousing
  • Design Adjustments
  • Error Modeling and Redesign
  • Bending
  • Cutting
  • Sonic Welding
  • Gluing/Solvent Bonding
  • Drilling
  • Milling
  • Stamping
  • Embossing
  • Polishing
  • Application of Decals
  • Printing
  • Quality Assurance
  • Assembly
  • Packaging


Molded Products

  Molded Products   Molded Products   Molded Products  

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Thermoformed Products

  Thermoformed Fab Products   Thermoformed Fab Products   Thermoformed Fab Products  

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