Custom Plastic Fabrication Services

Plastic fabricators transform raw plastic materials into finished custom components through processes like thermoforming, CNC trimming, heat bending, bonding, and assembly. At Hill Plastics, we use advanced CNC routers, vacuum forming equipment, and precision tooling to produce parts ranging from custom enclosures and machine guards to radome housings and OEM components. Our fabrication services include drilling, fastener installation, edge finishing, and secondary operations to deliver assembly-ready parts that meet exact drawing specifications for aerospace, medical, telecommunications, and industrial applications.

Acrylic and Plexiglass are actually the same material—Plexiglass is simply a brand name for acrylic (polymethyl methacrylate or PMMA). Both offer excellent optical clarity, impact resistance, and weatherability. At Hill Plastics, we work with various plastic materials including ABS, PETG, HDPE, and specialty formulations like UV-resistant ASA for outdoor applications. Our engineering team helps you select the optimal material based on your specific requirements for strength, chemical resistance, temperature tolerance, and environmental exposure to ensure the best performance for your application.

Prototype timelines depend on design complexity, but Hill Plastics typically produces prototypes within a few weeks. We use low-cost wood or polyurethane tooling that can be CNC-milled to your specifications quickly, allowing for rapid design validation. Once the master pattern is mounted on a mold base, we can thermoform or fabricate sample parts for your review. This fast-turnaround approach enables you to evaluate fit, function, and appearance before committing to production tooling, and design modifications can be easily incorporated at this stage.

Hill Plastics works with a comprehensive range of thermoplastic materials including ABS (Acrylonitrile-Butadiene-Styrene), HDPE (High-Density Polyethylene), PETG (Polyethylene Terephthalate Glycol), high-temperature ABS, UV-resistant ASA/ABS, decorative foil-laminated materials, polystyrene, and KYDEX. Our engineering team evaluates your application requirements—including impact resistance, tensile strength, chemical resistance, temperature tolerance, and environmental exposure—to recommend the most cost-effective material that meets your performance specifications. We also work with custom formulations and specialty materials for unique applications.

Yes, Hill Plastics supports production runs from single prototypes to high-volume manufacturing of thousands of parts. Our facility houses eight thermoforming machines ranging from 2'x3' to 5'x9', including a 4'x7' rotary thermoformer with cycle times 2.5 times faster than standard equipment for efficient high-volume production. With over 20,000 square feet of manufacturing space and decades of experience, we scale our processes to match your exact quantity requirements while maintaining competitive pricing and rigorous quality control throughout every production stage.

Hill Plastics serves a diverse range of industries including aerospace and aviation, telecommunications, medical devices and healthcare, industrial equipment and OEM manufacturing, defense and military, point-of-purchase and retail display, marine, electronics and electrical equipment, oil and gas/energy, and transportation and logistics equipment. Our client portfolio includes major companies like Southwest Airlines, CommScope, and LifePort. We provide custom thermoformed enclosures, radomes, material handling trays, machine guards, and precision OEM components tailored to each industry's specific regulatory, performance, and durability requirements.

Thermoforming offers significantly lower tooling costs compared to injection molding or rotomolding, especially for large parts. Hill Plastics uses CNC-milled wood patterns for prototyping that cost a fraction of metal injection molds, and even production aluminum tooling is more economical. The process enables cost-effective manufacturing of large components—up to 5'x9' in our facility—that would be prohibitively expensive with other methods. Short lead times for tooling, typically weeks rather than months, reduce time-to-market costs. For production runs from dozens to thousands of parts, thermoforming delivers excellent per-unit economics with minimal upfront investment.

Absolutely. Hill Plastics provides comprehensive design assistance and engineering support throughout your project. Our sales and engineering team, including Brad and Cody Hill, works with you to optimize designs for thermoformability, recommend proper tooling approaches, and select materials that balance performance with cost-effectiveness. Using SolidWorks CAD software, we create detailed technical drawings and can suggest design modifications to improve manufacturability, reduce waste, or enhance part functionality. From initial concept through prototype validation to production, our engineering expertise ensures your custom plastic components are designed for success.