Thermoforming Sub-Assembly

From Forming to CNC to Finished Assemblies — Made in USA

Thermoforming doesn’t stop at shaping plastic. For many applications, true value is delivered when multiple formed components are assembled into a single, ready-to-install product.

At Om Raj Tech, we partner with Formed Solutions Inc to provide integrated sub-assembly capabilities alongside thermoforming and 5-axis CNC trimming—all manufactured in Michigan, USA.

This allows customers to reduce internal labor, simplify supply chains, and receive fully assembled thermoformed components instead of managing multiple vendors.

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Integrated Sub-Assembly After Thermoforming

Our sub-assembly capability is designed for thermoformed plastic components that require more than one formed part, attachment features, or functional bonding.

Typical workflow:

Thermoforming (vacuum, pressure, twin sheet, or compression)
Pre-trim or CNC trim for locating features
Custom fixtured sub-assembly
Final CNC trim for precision and alignment
Finished, ready-to-use assemblies

This controlled, in-house process ensures proper alignment, repeatability, and cosmetic consistency.

How We Perform Sub-Assembly

Custom Assembly Fixtures

We design and use dedicated fixtures to accurately locate and hold parts during assembly. Fixtures ensure:

Proper alignment of multiple components
Repeatable positioning across production runs
Reduced variation during bonding or attachment

Bonding & Adhesive Assembly

Depending on the application, we use:

Two-part epoxy adhesives
Adhesive bonding combined with mechanical pinning
Controlled clamping and curing processes

These methods create strong, durable bonds suitable for structural and functional applications.

CNC-Finished Assemblies

After assembly, components return to 5-axis CNC trimming for:

Final perimeter trimming
Cutting openings, tabs, or access features
Removing temporary alignment tabs
Ensuring precise final geometry

This ensures assemblies meet tight dimensional and cosmetic requirements.

Real Sub-Assembly Examples

Thermoformed Air Duct Assembly (Office Furniture)

Molded in two thermoformed halves
Pre-trimmed for locating holes
Placed into fixtures for alignment
Bonded using two-part epoxy adhesive
Clamped and cured
Final CNC trimming creates a finished air duct assembly

Used in conference rooms and meeting facilities, this approach delivers a complete, install-ready product.

Multi-Part Medical / Rehab Equipment Housing

Assembly consists of ~8 individual thermoformed components
Main housing, exterior claddings, light bezel, and cover
Parts bonded using adhesive and clamping fixtures
Attachment features integrated into the final assembly

This type of assembly supports medical and rehabilitation equipment, where alignment, strength, and appearance are critical.