mANUFACTURING PROCESSES
Thermoforming and 5-Axis Routing
Pro-Form excels at thermoforming; we design and produce a vast range of parts. We have 9 tech-forward thermoforming machines. We can go big if you need it —with the capability to form parts as large as 6 feet x 10 feet. We can go thick and thin as required, from .030 to .500 inches. Our materials cover the whole menu: HDPE, LDPE, ABS, HIPS and PP.
Our CNC 5-Axis routing has the capability to route or trim flat or complex geometrical parts, using any non-metallic material including foam, plastic and wood. Our CNC router can handle work with materials up to 6 feet x 10 feet in size.
Pro-Form also produces more than just custom packaging solutions. We've been making thermoformed plastic parts for over three decades! Click the button below to view our infographic "Pro-Form Innovates and Advances Thermoformed Parts" to learn more about our thermoforming expertise across a range of industries and parts:
Pro-Form’s advantages:
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CAPACITY: Among our tech-forward thermoforming equipment, we offer two-state-of-the-art, large capacity machines — one 6’x10’, the other 5’x9’.
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TECHNOLOGY: Latest technology thermoforming ovens for greater volume and speed.
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FLEXIBILITY: Pro-Form can do it all: from flat to complex geometric parts.
Frequently asked questions
What is thermoforming?
Thermoforming is a manufacturing process that shapes heated plastic sheets into custom forms using molds. Once the plastic is heated and formed into the desired shape, it is trimmed to create durable components such as trays, containers or protective packaging inserts. Thermoforming is widely used to create packaging that protects products while remaining lightweight and cost-effective.
What materials are used in thermoforming?
Thermoformed packaging can be produced using several durable plastic materials, including:
- High-density polyethylene (HDPE)
- Polypropylene (PP)
- ABS plastics
- Specialty engineered plastics
The best material depends on the weight of the product, environmental conditions and the level of durability required.
What industries commonly use thermoformed packaging?
Thermoformed packaging is commonly used in industries where parts must move safely through manufacturing and transportation systems, including:
- Automotive manufacturing
- Aerospace
- Heavy equipment
- Industrial manufacturing
- Electronics and precision components
These industries rely on thermoformed trays and containers to protect products and maintain organization throughout the supply chain.
What are the advantages of thermoformed packaging?
Thermoformed packaging offers several benefits for manufacturers, including:
- Strong and durable product protection
- Lightweight materials that reduce shipping costs
- Custom designs that match product dimensions
- Compatibility with returnable packaging systems
- Efficient stacking and storage
These advantages make thermoforming a popular choice for industrial packaging solutions.
Can thermoformed packaging be reused?
Yes. Many thermoformed packaging solutions are designed to be reused repeatedly within returnable supply chains. Durable materials and engineered designs allow trays and containers to withstand multiple shipping cycles while maintaining product protection.
Does Pro-Form design thermoformed packaging in-house?
Yes. Pro-Form works closely with customers to design thermoformed packaging that fits their products and manufacturing processes. Our team uses engineering expertise and CAD design to develop packaging that protects parts while improving operational efficiency.
Can thermoformed packaging support automated manufacturing processes?
Yes. Thermoformed trays are often designed to maintain consistent part orientation, which supports automated assembly lines and robotic handling systems. Properly engineered packaging can help streamline manufacturing operations and reduce handling time.
How does Pro-Form ensure thermoformed packaging protects products?
Pro-Form engineers packaging around the exact shape, weight and handling requirements of the product. Our team evaluates transportation conditions, stacking requirements and supply chain workflows to ensure that parts remain secure during shipping and storage.