Pressure thermoforming combines vacuum forming with positive air pressure to force heated plastic sheets into temperature-controlled aluminum molds. Unlike standard vacuum forming, pressure forming allows us to capture fine textures, tight radii, and sharp corners, producing parts that closely resemble injection-molded components.
Key process highlights:
Tooling built to the A-side of the part (typically female aluminum molds)
Vacuum pulls the sheet into the cavity
Positive air pressure up to 80 PSI pushes plastic into fine details
Mold textures can be acid-etched for consistent cosmetic finishes
Supports wall thicknesses from thin gauge up to ~6 mm
This video walks through a real pressure-formed enclosure, showing both left-hand and right-hand components and explaining how pressure forming delivers superior aesthetics.
In the video, you’ll see:
How heated plastic exits the oven and enters the forming station
The mold pulling vacuum to draw plastic into the cavity
A pressure box sealing and applying up to 80 PSI of air pressure
The difference between the A-side (tool-contact side) and B-side (air-pressure side)
Why pressure forming is preferred for medical enclosures, dash panels, and cosmetic housings
This pressure thermoforming process is commonly selected when customers need parts that look injection molded but don’t justify injection tooling.
Our pressure thermoforming capability is not just about forming plastic—it’s about delivering finished, ready-to-assemble components.
Advanced Tooling & Process Control
Secondary Assembly & Value-Added Operations
We go beyond forming by offering:
This allows customers to receive functional, production-ready parts, not just formed shells
Pressure thermoforming is commonly used in applications that demand high aesthetics and performance, including:
Medical enclosures & housings
Automotive interior components & dash panels
Furniture and office equipment housings
Polycarbonate covers and flares
Prototypes and low-to-medium volume cosmetic parts
If your product requires clean textures, crisp edges, and premium appearance, pressure thermoforming is often the best fit.
Injection-mold-like appearance at lower tooling cost
Excellent for low-to-medium production volumes
Supports thicker gauge materials and tight radii
Faster tooling lead times than injection molding
Made in USA manufacturing in Holland, Michigan
If you’re searching for a pressure thermoforming manufacturer, pressure forming plastic near me, or a Made in USA thermoforming partner, Om Raj Tech offer the experience, capacity, and finishing capabilities to support your program from prototype to production.