Compression thermoforming is used when the raw material cannot stretch like standard thermoplastic sheets.
In this process, the material is typically:
A woven fiberglass fabric
Pre-impregnated with a thermoplastic resin
Because the fiberglass reinforcement prevents material stretch, vacuum or air pressure alone cannot form the part. Instead, matched male and female tools physically compress the heated material into shape.
The result is a composite thermoplastic part with enhanced stiffness, strength, and dimensional stability.
Composite Material Heating
Fiberglass-reinforced thermoplastic sheets are heated to the correct forming temperature.
Matched Tool Compression
A male and female mold close together, physically squeezing the material into the final geometry.
Material Consolidation
Compression forces the composite into corners, contours, and structural features without stretching fibers.
Cooling & Release
The part cools under compression, locking in strength and shape.
CNC Trimming & Finishing
Finished parts are trimmed using 5-axis CNC machines to create accurate perimeters, openings, and assembly features.
Compression thermoforming is chosen when applications require structural performance beyond standard thermoforming.
Key advantages include:
High strength and rigidity
Reinforced fiberglass structure
Minimal material stretch or thinning
Excellent dimensional stability
Durable performance under load
This process is commonly used to replace metal fabrications or multi-piece assemblies while reducing weight.
Compression thermoforming is often used for:
Air ducts and airflow components
Structural composite housings
Reinforced industrial components
Parts requiring stiffness and heat resistance
Applications where plastic alone is not sufficient
A common example includes air duct assemblies, where multiple compression-formed halves are later bonded into a single functional component.
Many compression thermoformed parts are produced as multiple sections due to geometry or tooling constraints.
We support:
Adhesive bonding of composite halves
Welding or fixture-based assembly
CNC trimming after bonding to ensure final accuracy
This integrated approach allows customers to receive finished composite assemblies, not just individual molded pieces.
All compression thermoforming, CNC trimming, and sub-assembly operations are performed at Formed Solutions Inc in Michigan, supporting customers who prioritize:
Domestic manufacturing
Supply-chain reliability
Consistent quality
Engineering collaboration
📩 Contact Om Raj Tech to discuss your compression thermoforming or fiberglass-reinforced thermoplastic project.