Thermoforming & Vacuum Forming
We form custom plastic enclosures using eight thermoforming machines ranging from 2'x3' to 5'x9', producing precise, durable housings in materials like ABS, HDPE, and KYDEX for industrial and OEM applications.
From rugged industrial housings to precision-formed radome enclosures, Hill Plastics delivers custom plastic enclosures engineered to your exact specifications. Serving OEM manufacturers, aerospace, telecommunications, and industrial markets across the U.S., our 45-year legacy of thermoforming expertise means your enclosures are built with accuracy, durability, and cost-effective production from prototype to full-volume runs.
From vacuum forming to precision CNC finishing, we deliver end-to-end enclosure manufacturing tailored to your specifications.
We form custom plastic enclosures using eight thermoforming machines ranging from 2'x3' to 5'x9', producing precise, durable housings in materials like ABS, HDPE, and KYDEX for industrial and OEM applications.
Our two 5'x10' CNC trimming centers deliver enclosure components trimmed to exact drawing specifications, with contour cutting, precision drilling, edge finishing, and fastener preparation for assembly-ready parts.
Our skilled fabrication team performs heat bending, bonding, riveting, and threaded insert installation to produce fully finished custom enclosures that meet your design, structural, and dimensional requirements.
We build low-cost wood and polyurethane molds for prototype enclosures and aluminum production tooling for high-volume runs, supporting every stage from initial design review through final production approval.
Using low-cost wood master patterns CNC-milled to print specifications, we produce functional enclosure prototypes in just weeks, allowing design review, fit evaluation, and fast iteration before committing to production tooling.
Our 4'x7' rotary thermoforming machine runs 2.5x faster than standard single-station equipment, enabling cost-effective, quality-controlled high-volume enclosure production from thousands of units with competitive pricing.
Our sales and engineering team — Brad Hill and Cody Hill — work directly with you to understand your enclosure application, dimensional requirements, environmental conditions, and industry-specific standards, whether you're in aerospace, telecom, medical, or industrial OEM manufacturing.
See how Hill Plastics has delivered precision enclosures and fabricated parts for leading OEMs, aerospace, and telecom companies.
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
For over four decades, Hill Plastics has earned the trust of engineers and purchasing agents across the U.S. with consistent quality, competitive pricing, and genuine manufacturing expertise.
Founded in 1977, our team brings decades of thermoforming and enclosure fabrication knowledge that newer manufacturers simply cannot match.
Eight thermoforming machines, two 5'x10' CNC trimming centers, and a high-speed rotary former give us capacity and precision for any order size.
Our wood and polyurethane prototype tooling keeps your upfront investment minimal while delivering production-accurate enclosure prototypes in just weeks.
Operating from our 20,000+ sq. ft. facility in Lewisville, TX, we ship precision enclosures to OEM manufacturers and industrial clients nationwide.
Experienced engineers ready to solve your toughest enclosure challenges.
Sales & Engineering Team
Brad Hill brings deep expertise in plastic thermoforming design and materials engineering to every customer project. As a key member of Hill Plastics' sales and engineering team, Brad specializes in helping clients navigate the complexities of material selection—evaluating cost, impact requirements, durability, tensile strength, chemical resistance, and environmental factors to identify the optimal PS or HIPS grade for each unique application. He works closely with customers from initial concept through prototype approval, offering guidance on tooling design, process optimization, and production planning. Brad's hands-on approach ensures that every thermoformed component is engineered for performance, manufacturability, and cost-effectiveness. His commitment to collaborative problem-solving and technical precision has made him a trusted advisor to OEM manufacturers, aerospace clients, and medical device companies nationwide. With a focus on delivering turnkey solutions that meet exact specifications, Brad exemplifies Hill Plastics' dedication to quality, innovation, and customer success.
Sales & Engineering Team
Cody Hill is a skilled plastics engineer and sales professional with a passion for transforming customer ideas into precision-manufactured reality. As part of Hill Plastics' dedicated sales and engineering team, Cody provides expert consultation on product design, material selection, and tooling strategy for custom thermoforming projects. He leverages advanced CAD tools like SolidWorks to collaborate with clients on design refinements, ensuring optimal part geometry, wall thickness distribution, and draft angles for successful vacuum forming. Cody's technical knowledge spans the full spectrum of PS and HIPS materials, enabling him to recommend the best plastic grade based on application-specific demands such as impact resistance, rigidity, clarity, and cost. From rapid prototyping using low-cost tooling to scaling up for high-volume production runs, Cody guides customers through every phase of the manufacturing process with transparency and attention to detail. His proactive communication style and commitment to delivering on-time, on-budget results have earned him the trust of clients across aerospace, telecommunications, industrial equipment, and medical device sectors.
Hill Plastics produces a wide range of custom plastic enclosures including industrial housings, radome enclosures, OEM equipment covers, machine guards, and application-specific enclosures for aerospace, telecommunications, medical, and marine industries. Enclosures can be thermoformed or fabricated from materials such as ABS, HDPE, PETG, KYDEX, and UV-resistant ASA/ABS, and are trimmed and finished to exact drawing specifications.
Talk to our engineering team for a no-obligation consultation and quote.
Hill Plastics ships precision custom enclosures and fabricated parts to customers across the entire United States.
Nationwide U.S.
Service Coverage
Mon–Fri, 7AM–4:30PM
Business Hours
20,000+ Sq Ft
Manufacturing Space
Contact us to confirm we can fulfill your custom enclosure requirements.
Trusted plastic thermoforming manufacturer since 1977
Advanced CAD and CNC interface certified manufacturing
Custom quality control system monitoring all production stages
Share your enclosure requirements and our engineering team will respond with material recommendations, tooling options, lead time estimates, and competitive pricing — no obligation required.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.