Custom Thermoformed Enclosures
We vacuum-form and heavy-gauge thermoform ruggedized server enclosures to exact military specifications, using materials like high-temp ABS and UV-resistant ASA/ABS built for demanding tactical environments.
Defense applications demand enclosures built to survive—not just perform. Hill Plastics engineers custom military server enclosures using precision thermoforming, CNC fabrication, and ruggedized materials engineered to meet the exacting tolerances of defense and tactical environments. From prototyping to high-volume production, we deliver mission-critical plastic solutions that hold up where it counts.
From prototype to production, we deliver precision plastic enclosure solutions engineered for defense and military-grade requirements.
We vacuum-form and heavy-gauge thermoform ruggedized server enclosures to exact military specifications, using materials like high-temp ABS and UV-resistant ASA/ABS built for demanding tactical environments.
Our two 5'x10' CNC trimming centers deliver precision-cut enclosure panels with clean edges, accurate drill patterns, and assembly-ready finishing for defense OEM components.
We produce low-cost prototype tooling and production-grade aluminum molds for military enclosure programs, enabling rapid iteration and cost-controlled transition from design to approved production parts.
Using low-cost wood and polyurethane tooling, we produce accurate enclosure prototypes for design review and functional evaluation, often delivering a master pattern within just a few weeks.
Our 4'x7' rotary thermoforming machine runs 2.5x faster than standard single-station equipment, enabling cost-effective high-volume military enclosure production with consistent quality control throughout every run.
Our sales and engineering team helps select the right materials—evaluating impact resistance, tensile strength, and environmental durability—to ensure every military server enclosure meets application-specific performance requirements.
Our engineering team—Brad and Cody Hill—reviews your military server enclosure specifications, drawing requirements, and environmental performance criteria to ensure every design decision aligns with your defense application's demands from day one.
See how Hill Plastics delivers precision-engineered enclosures that meet the toughest military and defense requirements.
"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 manufacturing experience and a facility built for precision, Hill Plastics is a proven partner for defense-grade plastic enclosure solutions.
Founded in 1977, our team brings decades of applied experience producing enclosures for defense, aerospace, and industrial OEM programs.
We stock and process high-temp ABS, UV-resistant ASA/ABS, KYDEX, and HDPE—materials selected specifically for ruggedized military applications.
From design consultation and prototyping to production tooling and fulfillment, we manage your entire enclosure program under one roof in Lewisville, Texas.
Our rotary thermoforming equipment and 20,000+ sq. ft. facility support scalable military enclosure programs, from short prototype runs to thousands of production units.
Experienced engineers dedicated to precision defense enclosure solutions.
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.
We use a range of materials suited for defense applications, including high-temperature ABS, UV-resistant ASA/ABS, KYDEX, HDPE, and PETG. Material selection is based on your enclosure's specific requirements—impact resistance, tensile strength, chemical exposure, and environmental conditions are all evaluated to ensure the best fit for military deployment.
Speak directly with our engineering team for application-specific guidance and a custom quote.
Hill Plastics ships custom military enclosures and defense plastic components to customers across the United States.
Nationwide USA
Service Area
20,000+ Sq. Ft.
Manufacturing Facility
45+ Years
Years Serving Defense
We ship finished defense enclosures and plastic components to customers across the country.
Established in 1977, a proven industry leader.
SolidWorks-powered design and CNC interface.
Trusted supplier to defense and aerospace OEMs.
Share your project specifications, drawing requirements, and production volumes with our engineering team. We'll respond with a detailed quote and design recommendations tailored to your defense application.
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.