Mold Making & Tooling
Custom molds crafted from aluminum, polyurethane, wood, and Renshape tooling board. We assist with design and development, producing prototype and production tooling tailored to your exact drawing specifications.
From low-cost prototype tooling to precision aluminum production molds, Hill Plastics delivers end-to-end tooling solutions built for accuracy and repeatability. Serving OEM manufacturers, aerospace, telecom, medical, and industrial clients across the country, our Lewisville, Texas facility combines 45 years of expertise with advanced CNC machinery to take your product from concept to finished part — on time and on budget.
Comprehensive tooling solutions from first-run prototypes to high-volume production molds — engineered for precision, speed, and cost efficiency.
Custom molds crafted from aluminum, polyurethane, wood, and Renshape tooling board. We assist with design and development, producing prototype and production tooling tailored to your exact drawing specifications.
Rapidly produce prototypes using low-cost wood or polyurethane tooling for design review and functional evaluation. Master patterns are CNC-milled to print specs, with prototypes available in just a few weeks.
Precision CNC trimming and cutting using two 5'x10' trimming centers. Supports contour cutting, edge finishing, precision drilling, and assembly-ready part production for thermoformed and fabricated plastic components.
Eight thermoforming machines ranging from 2'x3' to 5'x9' form heated plastic sheets over custom tooling using vacuum pressure, delivering precise, repeatable parts trimmed to drawing specifications.
Our 4'x7' Rotary Thermoforming machine cycles 2.5x faster than standard single-station equipment, enabling cost-effective, quality-controlled high-volume production runs from prototype approval through fulfillment.
Our sales and engineering team evaluates your requirements to recommend optimal tooling design and material selection — covering impact resistance, durability, chemical resistance, and environmental factors for your application.
Our engineering team — led by Brad and Cody Hill — reviews your product requirements, drawings, and specifications. We recommend the right tooling approach, material selection, and design refinements before any material is cut, ensuring your project starts on the right foundation.
See how Hill Plastics has delivered precision tooling and production solutions for clients across aerospace, telecom, medical, and OEM manufacturing.
"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..."
Four decades of tooling expertise, an advanced Texas manufacturing facility, and a team committed to quality — here is what sets us apart.
Founded in 1977 and based in Lewisville, TX, our staff averages 20+ years of industry experience in thermoforming and tooling.
Wood and polyurethane prototype molds minimize your upfront investment, letting you validate design and function before committing to aluminum production tooling.
Over 20,000 sq. ft. of production space in Lewisville, TX, with eight thermoforming machines and two 5'x10' CNC trimming centers for any production volume.
From design consultation and prototype tooling through aluminum production molds and finished part fulfillment — we manage the entire process under one roof.
Our experienced engineers are ready to guide your project from first concept to final part.
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.
For prototypes and pre-production parts, Hill Plastics uses low-cost wood (Perfect Plank, Mahogany) and polyurethane tooling. A master pattern is CNC-milled to your print specifications and can typically be completed in a few weeks depending on design complexity. This approach allows fit and function review before investing in aluminum production tooling.
Speak directly with our engineering team for a no-obligation consultation on your project.
Continuously serving OEM and industrial clients since 1977.
Advanced CAD and CNC interface for precision tooling production.
Perfect 5-star customer rating reflecting quality and reliability.
Submit your project details or drawings and our engineering team will respond with tooling recommendations, lead time estimates, and competitive pricing — typically within one business day.
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.