The hollow design created through twin sheet thermoforming provides rigidity while keeping the overall weight low.
Twin sheet thermoforming is the ideal solution when plastic parts must be lightweight, strong, and structurally rigid without the cost and weight of solid plastic or metal assemblies.
At Om Raj Tech, we partner with Formed Solutions Inc to produce custom twin sheet thermoformed components, all manufactured in Michigan, USA. This twin sheet thermoforming process is widely used for applications that require stiffness, durability, and integrated structure.
If you’re searching for twin sheet thermoforming near you or Made in USA thermoforming, this capability is built specifically for structural performance.
Twin sheet thermoforming uses two heated plastic sheets formed simultaneously and welded together to create a hollow, rigid part.
Unlike single-sheet thermoforming, twin sheet forming produces:
Dual walls
A sealed perimeter weld
Increased stiffness without added material thickness
The twin sheet thermoforming result is a part that behaves more like a structural component than a cosmetic cover.
Two Plastic Sheets Heated Together
Two thermoplastic sheets are heated in the oven at the same time to precise forming temperatures.
Upper & Lower Mold Forming
One sheet is formed upward while the other is formed downward using matched molds.
Perimeter Welding
As the molds close, the sheets are pinched together, creating a continuous welded bond around the perimeter.
Cooling & Release
The hollow structure cools and maintains its shape, strength, and dimensional stability.
CNC Trimming & Finishing
Finished twin sheet parts are trimmed on 5-axis CNC machines for clean edges, openings, and mounting features.
Twin sheet thermoforming is selected when standard custom vacuum forming or pressure forming cannot provide enough rigidity, making twin sheet thermoforming services ideal for producing strong, durable parts using advanced custom plastic manufacturing machines.
Key advantages include:
High strength-to-weight ratio
Hollow internal structure
Reduced material usage compared to solid parts
Integrated ribs, bosses, and structural features using twin sheet thermoforming services
Excellent durability for industrial and outdoor environments
This twin sheet thermoforming process is often used to replace metal fabrications or multi-piece plastic assemblies.
Twin sheet thermoforming is commonly used in:
Industrial equipment enclosures
Structural housings and panels
Covers requiring stiffness and impact resistance
Outdoor and heavy-duty applications
Parts that would otherwise require internal frames or ribs
The hollow design created through twin sheet thermoforming provides rigidity while keeping the overall weight low.