Thermoforming & Vacuum Forming
Custom thermoforming and vacuum forming using eight machines ranging from 2'x3' to 5'x9'. Supports ABS, HDPE, PETG, KYDEX, and more for enclosures, OEM parts, trays, and industrial applications at any volume.
From initial design and low-cost prototype tooling to high-volume thermoforming and precision CNC fabrication, Hill Plastics delivers end-to-end plastic contract manufacturing trusted by OEM engineers, aerospace suppliers, and industrial buyers across the U.S. With over 45 years of experience and 20,000+ sq ft of production capacity near Dallas, we take your concept to finished part—on schedule and on budget.
Comprehensive plastic production capabilities from prototype tooling and design through high-volume thermoforming and precision CNC fabrication.
Custom thermoforming and vacuum forming using eight machines ranging from 2'x3' to 5'x9'. Supports ABS, HDPE, PETG, KYDEX, and more for enclosures, OEM parts, trays, and industrial applications at any volume.
Expert fabrication of custom POP displays, industrial parts, and secondary trim operations. Services include precision drilling, heat bending, bonding, fastener installation, and edge finishing to exact drawing specifications.
Precision CNC trimming and cutting using two 5'x10' trimming centers and automated router equipment. Delivers clean edges, dimensional accuracy, and repeatable quality for contour cutting and assembly-ready parts.
Custom molds and tooling from wood, polyurethane, and aluminum for prototypes through production. Includes CNC-milled master patterns, drill fixtures, trim fixtures, and threaded insert tooling.
Rapid prototypes from low-cost wood or polyurethane tooling, typically produced in just a few weeks. Perfect for design review, fit and function evaluation, and pre-production validation before committing to aluminum tooling.
Hands-on engineering support from Brad and Cody Hill to guide material selection—evaluating cost, impact resistance, durability, and chemical resistance—and tooling design for a turnkey solution from concept to finished part.
Our sales and engineering team—Brad and Cody Hill—work directly with your engineers and purchasing team to understand part requirements, tolerances, environmental conditions, and production volumes. SolidWorks is used to review or develop CAD models to print specifications.
See how OEM manufacturers, aerospace suppliers, and industrial buyers rely on Hill Plastics for precision parts and on-time delivery.
"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..."
For over four decades, Hill Plastics has been the contract manufacturing partner that engineers and purchasing agents trust for quality, precision, and competitive pricing.
Founded in 1977 near Dallas, our team brings decades of hands-on thermoforming and fabrication knowledge to every project.
From design and low-cost prototyping to high-volume production and fulfillment, we manage every stage under one roof.
Our 20,000+ sq ft Lewisville facility and rotary thermoformer running 2.5x standard speed keep U.S. OEM supply chains moving.
Low-cost wood and polyurethane prototype tooling means faster iteration and lower upfront investment before production aluminum molds are made.
Experienced engineers and sales professionals dedicated to your production success.
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.
Contract manufacturing costs depend on part complexity, material selection, tooling type, and production volume. At Hill Plastics, low-cost wood or polyurethane prototype tooling keeps upfront investment minimal, while aluminum production tooling is used for high-volume runs. We offer competitive pricing structured to fit OEM and industrial budgets, and our engineering team will work with you to find the most cost-effective approach for your application.
Talk to Brad or Cody directly for a no-obligation consultation on your plastic manufacturing needs.
Hill Plastics ships precision-manufactured plastic parts to OEM manufacturers and industrial buyers across the entire United States.
Lewisville, TX (DFW)
Headquarters
Nationwide U.S.
Service Area
20,000+ Sq Ft
Facility Size
We deliver finished plastic parts to customers nationwide—contact us to confirm logistics and lead times for your area.
Continuously serving OEM and industrial clients since 1977.
Engineering and CNC design supported by industry-standard SolidWorks software.
Perfect 5-star customer rating reflecting consistent quality and service.
Tell us about your part requirements, production volume, and timeline. Our engineering team will respond with a tailored recommendation and competitive pricing—no obligation required.
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.