Thermoforming & Vacuum Forming
We heat and vacuum-form plastic sheets into custom tanks and components using eight thermoforming machines ranging from 2'x3' to 5'x9', supporting ABS, HDPE, PETG, and more for low-cost, high-quality production.
Hill Plastics delivers precision custom plastic tank fabrication services built to exact specifications for industries across the United States. From OEM manufacturers and aerospace to medical and industrial applications, our expert team combines 45+ years of thermoforming and fabrication expertise with advanced CNC equipment to produce durable, high-quality plastic components — on time and within budget.
From precision thermoforming to full CNC fabrication, we deliver complete custom plastic solutions for every production need.
We heat and vacuum-form plastic sheets into custom tanks and components using eight thermoforming machines ranging from 2'x3' to 5'x9', supporting ABS, HDPE, PETG, and more for low-cost, high-quality production.
Our skilled fabrication department produces custom plastic parts using precision CNC trimming, drilling, bonding, heat bending, and edge finishing — delivering finished components ready for assembly or direct deployment.
Using two 5'x10' CNC trimming centers and advanced routing machinery, we trim and cut thermoformed and fabricated plastic parts to exact drawing specifications with clean edges and repeatable dimensional accuracy.
We design and fabricate custom molds using aluminum, polyurethane, and precision wood tooling. From low-cost prototype molds to production-grade aluminum tools, we support every stage of your product development.
Produce accurate prototypes from low-cost wood or polyurethane tooling within weeks. Our prototyping process lets you review fit and function before committing to full production tooling, minimizing risk and cost.
Our 4'x7' rotary thermoforming machine runs 2.5x faster than standard single-station equipment, enabling cost-effective high-volume plastic tank and component production with strict quality control at every stage.
Our sales and engineering team — Brad and Cody Hill — work directly with you to understand your product requirements, application environment, and performance specifications, translating your concept into a detailed fabrication plan.
See how Hill Plastics has delivered precision plastic fabrication solutions for leading manufacturers and OEMs.
"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 proven expertise, here's what sets Hill Plastics apart for custom plastic tank fabrication.
Founded in 1977 near Dallas/DFW, our team brings minimum 20-year tenures and deep domain knowledge across aerospace, industrial, and OEM plastic fabrication.
Eight thermoforming machines, two 5'x10' CNC trimming centers, and a rotary thermoformer 2.5x faster than standard equipment ensure precision and capacity for any production volume.
From initial design and material selection through prototyping, tooling, production, and fulfillment — we manage every step, delivering finished plastic parts ready for use across the United States.
Our wood and polyurethane prototype tooling minimizes upfront investment, letting U.S.-based OEMs and entrepreneurs validate designs cost-effectively before committing to full aluminum production molds.
Expert engineers dedicated to delivering precision plastic fabrication 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.
Hill Plastics works with a wide range of thermoplastic materials including ABS, High-Density Polyethylene (HDPE), PETG, High Temperature ABS, UV Resistant ASA/ABS, Polystyrene, KYDEX, and decorative foil laminated materials. Material selection is based on your application's requirements for impact resistance, tensile strength, chemical resistance, durability, and environmental conditions.
Talk to our engineering team for a free consultation and project quote.
Hill Plastics fabricates and ships custom plastic tanks and components to clients across the entire United States.
Nationwide U.S.
Service Coverage
Lewisville, TX
Headquarters
Mon–Fri, 7AM–4:30PM
Business Hours
We serve customers across the U.S. — contact us to confirm delivery and discuss your project.
Serving OEM manufacturers and industrial clients since 1977.
Advanced design and CNC interface using industry-leading SolidWorks software.
High-capacity manufacturing space supporting prototype through high-volume production.
Fill out the form below to describe your project requirements and one of our engineers will get back to you promptly with a tailored solution and competitive quote.
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.