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Vacuum Forming

Custom Vacuum Formed Plastic Parts – Made in USA

Vacuum thermoforming is one of the most versatile and cost-effective plastic forming processes available today. At Om Raj Tech, we partner with Formed Solutions Inc to deliver high-quality vacuum thermoformed parts manufactured entirely in Michigan.

This page explains how vacuum thermoforming works, where it’s best used, real project examples, and answers common questions buyers have when searching for vacuum thermoforming near me.

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    How We Do Vacuum Thermoforming

    Vacuum thermoforming is a single-sided thermoforming process where tooling is built to the B-side of the part, meaning the A-side (cosmetic surface) never touches the mold.

    1. Plastic Sheet Heating
      A flat thermoplastic sheet (ABS, PETG, acrylic, polycarbonate, HIPS, TPO, nylon, Ultem, and more) is heated in an oven until it reaches the ideal forming temperature.

    2. Forming Over the Mold
      The heated sheet is transferred to the forming station where a positive mold rises into the sheet, creating a tight perimeter seal.

    3. Vacuum Application
      Vacuum is applied, pulling the plastic sheet down and around the mold surface to form the part’s shape.

    4. Cooling & Release
      Once cooled, the formed part is released from the mold while maintaining dimensional stability.

    5. 5-Axis CNC Trimming
      All vacuum formed parts are precision-trimmed using in-house 5-axis CNC machines to create clean edges, cutouts, holes, and mounting features.

    This process allows for lower tooling costs, faster lead times, and efficient production of large or complex-shaped plastic parts.

    Vacuum Thermoforming Project Examples

    Our vacuum thermoforming capabilities support a wide range of industries. Below are real-world examples referenced in the video content used on this page.

    Marine & Recreational Products

    • Pontoon boat docking lights with decorative films

    • Marine covers and housings

    • Lightweight, corrosion-resistant components designed for outdoor environments

    Automotive & Specialty Vehicles

    • Fire truck steering column covers formed in textured ABS

    • Large-format automotive covers and panels

    • Durable parts designed for vibration, heat, and daily use

    Industrial & Equipment Enclosures

    • Industrial plastic covers and housings

    • Functional enclosures with secondary fasteners installed

    • Parts designed for durability, repeatability, and ease of assembly

    Clear & Transparent Vacuum Formed Parts

    • Clear plastic enclosures using acrylic, PETG, and polycarbonate

    • Applications requiring visibility, light transmission, or protective shielding

    Vacuum thermoforming allows us to support low to medium volume programs across automotive, marine, industrial, medical, furniture, recreational, and fitness markets.

    Pontoon Boat Light Made from Vacuum Forming
    Fan Covers
    Image of Formed Fire Truck part
    Acrylic Dome Skylight Window at Flat Roof
    Vacuum Formed Part
    Vacuum Formed and CNC Trimmed part

    What is Vacuum Thermoforming?

    Vacuum thermoforming is a plastic manufacturing process where a heated thermoplastic sheet is formed over a mold using vacuum pressure. It is one of the most commonly used thermoforming methods due to its simplicity, scalability, and cost efficiency.

    Key Advantages of Vacuum Thermoforming

    • Lower tooling costs compared to injection molding

    • Faster tooling and production lead times

    • Ideal for large parts and deep draws (within draw ratio limits)

    • Supports a wide range of thermoplastic materials

    • Excellent option for Made in USA manufacturing

    Typical Applications

    • Equipment covers and housings

    • Automotive and transportation components

    • Marine and recreational products

    • Industrial enclosures

    • Medical and clear plastic components

    If you’re comparing vacuum forming vs pressure forming, vacuum forming is best suited when extreme surface detail or Class-A finishes are not required, but durability, speed, and cost control are critical.

     

    Our thermoforming process is designed for versatility across a broad spectrum of industries. We work with specialized resins for fire-retardant applications—using materials such as FR-grade ABS and fire-retardant polycarbonate—to meet stringent safety and performance standards in sectors including automotive, building and construction, electrical enclosures, HVAC components, industrial control panels, aerospace interiors, and marine equipment. Additionally, our process accommodates impact-resistant plastic resins that offer lightweight yet durable alternatives to traditional materials like metal and fiberglass, making them ideal for applications such as go-karts where replacing fiberglass with impact-resistant plastics enhances safety and reduces weight without compromising strength.

    What materials can be vacuum thermoformed?

    We commonly vacuum form ABS, PETG, acrylic, polycarbonate, high-impact polystyrene (HIPS), polyethylene TPO, nylon, and higher-engineered plastics depending on the application.

    Yes. Vacuum thermoforming is one of the best options for low to medium volume production, prototypes, and programs where tooling investment needs to stay low.

    Yes. All vacuum thermoforming is performed at Formed Solutions Inc in Michigan, supporting customers looking for Made in USA or domestic manufacturing partners.

    Vacuum thermoforming has lower tooling costs and faster lead times, making it ideal for lower volumes. Injection molding is better suited for very high volumes and parts requiring molded-in features.

    Absolutely. All parts are CNC-trimmed, and additional machining, cutouts, and mounting features can be added post-forming.

    Vacuum thermoforming supports both small and very large parts. Large-format machines allow forming parts measured in feet rather than inches.

    Vacuum Thermoforming FAQ