Custom Thermoforming

Thermoforming is a process where an extruded sheet of plastic is heated to a specific forming temperature, formed to the shape of either a female or male mold and then trimmed to fit the desired, detailed finished product. It involves far less tooling and investment than other plastic molding processes, making it an advantageous means of production.

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Types of Thermoforming

Thermoforming processes performed at Bo-Mer include:

Vacuum Forming

Pressure Forming

Drape Forming

Membrane Press Forming

Free Forming

Here at Bo-Mer, we’ve used these processes to bring anything from robots to medical imaging equipment to life.


Custom Thermoforming vs Injection Molding:

Custom thermoforming has a much lower initial tooling cost than other plastic processes, like injection molding. Quick turn prototypes in an economical fashion.

Custom Thermoforming vs Sheet Metal Fabrication:

With thermoforming, you can also add style and functionality that isn’t possible to achieve with metal fabrication.

Our Thermoforming Equipment

  • 3 rotary thermoforming machines that can accommodate up to a 6’ x 10’ x 41” depth.
  • 10 single station thermoforming machines that can accommodate up to a 7’ x 11’ x 40” depth.
  • Two inline (thin gauge) thermoforming machines.

The Process

Steps to Bring your Project to Life

  1. Design and onboarding: We’ll sit down with you and review your design and project scope and goals. We’ll help you refine your design and your CAD files to assure the manufacturability at the most economical cost. We ensure there is a plan in place to make the manufacturing process seamless.
  2. Materials selection: Our experts will help you choose the right plastics for your job. We want you to be happy with both the function and aesthetics of the final product.
  3. Tooling: We create a mold from your design. Depending on the volume and complexity, various medias are looked at for tooling, ranging from wood and epoxy boards to fabricated or cast temperature-controlled aluminum. When fabricating your mold, our goal is to include as many individual parts into the mold as we can, to reduce the end cost to our customers.
  4. Thermoforming: When the mold is complete, it’s time to bring your project to life. We heat the plastic chosen for your job to a pliable temperature and then use vacuum and possibly air pressure to shape the plastic to your mold. Once the plastic has cooled, we remove from the mold and trim any excess material.
  5. Value added assembly: Often times after a customer’s plastic project is thermoformed and trimmed, the design requires additional assembly services. We offer a plethora of secondary manufacturing options so you can work with a single partner to bring your project to life.

Do You Have A Project We Can Help With?

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