Thermoforming & Vacuum Forming
We produce durable custom generator enclosures using vacuum and heavy-gauge thermoforming with eight machines up to 5'x9'. Materials include ABS, HDPE, PETG, and UV-resistant ASA/ABS for outdoor protection.
Hill Plastics has manufactured precision custom generator enclosures since 1977, serving OEM manufacturers and industrial clients across the United States. From rugged outdoor housing to compact acoustic shrouds, our thermoformed and fabricated plastic enclosures are engineered to your exact specifications—delivering lasting protection, repeatable quality, and competitive pricing from our 20,000 sq ft Texas facility.
From prototype to high-volume production, we deliver precision-engineered plastic generator enclosures tailored to your specifications.
We produce durable custom generator enclosures using vacuum and heavy-gauge thermoforming with eight machines up to 5'x9'. Materials include ABS, HDPE, PETG, and UV-resistant ASA/ABS for outdoor protection.
Our fabrication department delivers finished enclosure components with precision CNC trimming, drilling, heat bending, bonding, and fastener installation—ready for assembly straight off the production floor.
We design and build custom molds from wood, polyurethane, or aluminum tooling. Low-cost prototype tooling allows fast design validation before committing to full production runs.
Using two 5'x10' CNC trimming centers and SolidWorks CAD integration, we deliver dimensionally accurate enclosure panels with clean edges, contour cuts, and repeatable production quality.
Rapidly produce enclosure prototypes using low-cost wood or polyurethane tooling. Master patterns are CNC-milled to print specs, allowing design review and functional testing in just a few weeks.
Our 4'x7' rotary thermoforming machine runs 2.5x faster than standard equipment, enabling cost-effective, large-volume generator enclosure production with rigorous quality control at every stage.
Our sales and engineering team—Brad and Cody Hill—work directly with you to understand your generator enclosure requirements, environmental conditions, load specs, and dimensional tolerances. We use SolidWorks to translate your ideas into precise, manufacturable designs.
See how engineers and purchasing teams across the U.S. rely on Hill Plastics for enclosure quality and precision.
"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..."
With over four decades of thermoforming expertise and a fully equipped Texas manufacturing facility, Hill Plastics delivers generator enclosures that meet your exacting standards.
Since 1977, Hill Plastics has engineered enclosures for demanding industrial and OEM applications across the United States.
From initial concept through material selection, tooling, production, and shipping—we manage your entire enclosure project under one roof in Lewisville, TX.
Our 20,000 sq ft facility with eight thermoforming machines handles both short-run prototypes and large-volume production orders at competitive prices.
A custom quality control system monitors every production stage, ensuring each generator enclosure meets print specifications for appearance, dimensions, and durability.
Experienced engineers dedicated to delivering your custom enclosure solution.
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.
A generator zombie box is a slang term for a custom weatherproof or acoustic enclosure built to house a generator—protecting it from the elements while reducing noise and improving safety. These enclosures are typically made from durable thermoformed plastics like ABS or HDPE and are engineered to allow adequate ventilation and fuel access while meeting specific dimensional and performance requirements.
Speak directly with our engineering team for a free consultation and custom quote.
Based in Lewisville, TX, Hill Plastics ships custom generator enclosures to clients across the entire United States.
Nationwide U.S.
Service Coverage
20,000+ Sq Ft
Manufacturing Facility
45+ Years
Years in Business
Contact our Lewisville, TX team to discuss your project and get a competitive quote.
Serving OEM and industrial clients since 1977.
Advanced CAD and CNC interface for precision manufacturing.
Custom quality control system monitors all production stages.
Share your enclosure specifications, dimensions, and production volume with our engineering team. We'll respond promptly with material recommendations, tooling options, and a competitive quote tailored to your project.
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.