Exploring the World of Custom Plastic Thermoforming: A Comprehensive Guide to the Process, Applications, and Products

Custom plastic thermoforming is a manufacturing process used to shape thermoplastic sheets into specific forms by heating the material until it becomes pliable and then molding it into the desired shape. This process is widely used to create a variety of products with different sizes, shapes, and complexities. At MarCon Solutions, we can help you at every step, from material selection to cooling and trimming. Entrust the entire process to our competent in-house teams; our staff is ready to assist in all of the following:

Material Selection:

  • Thermoforming typically uses thermoplastic sheets, such as ABS (Acrylonitrile Butadiene Styrene), PETG (Polyethylene Terephthalate Glycol), PVC (Polyvinyl Chloride), and polycarbonate. The choice of material depends on the specific properties required for the final product.

Heating the Plastic Sheet:

  • The chosen thermoplastic sheet is heated until it reaches its softening or forming temperature. This temperature varies depending on the material used.


  • Once the plastic sheet is heated and pliable, it is transferred to a mold. The mold can be a single-sided mold or a two-sided mold, depending on the complexity of the desired shape. The mold is typically made from materials like aluminum or composite.

Vacuum Forming or Pressure Forming:

  • The thermoforming process can be categorized into two main types: vacuum forming and pressure forming. Vacuum Forming: In this process, the heated plastic sheet is drawn onto or into a mold by vacuum pressure. This is suitable for products with simple shapes and relatively shallow depths.
  • Pressure Forming: In pressure forming, additional pressure is applied to the plastic sheet during the forming process. This allows for more intricate and detailed parts with sharper definition.

Cooling and Trimming:

  • After the plastic has taken the shape of the mold, it is cooled to solidify and retain the formed shape. The excess material is then trimmed away to create the final product.

Secondary Operations (Optional):

  • Depending on the product requirements, secondary operations such as machining, printing, or assembly may be performed after the initial thermoforming process.

Our custom plastic solutions can be used in all of the following:


  • Packaging: Thermoforming is commonly used for creating blister packs, clamshells, and other types of packaging for consumer goods.
  • Automotive Components: Interior components, like dashboards and door panels, as well as exterior parts, can be manufactured using thermoforming.
  • Medical Devices: Thermoforming is used to produce various medical device components and packaging.
  • Appliance Parts: Many plastic components in household appliances are manufactured using thermoforming.
  • Point-of-Purchase Displays: Custom displays for retail environments are often created through thermoforming.

Custom plastic thermoforming is favored for its cost-effectiveness, rapid prototyping capabilities, and versatility in producing both small and large parts with varying levels of complexity. MarCon Solutions is your reliable partner in the realm of custom plastic thermoforming, offering expertise and tailored solutions to bring your unique visions to life. With a commitment to precision, quality, and innovation, MarCon Solutions is poised to assist in realizing diverse products across industries, ensuring excellence in the design, production, and delivery of thermoformed solutions. Call us today!