Thermoforming & Vacuum Forming
Custom thermoforming and vacuum forming using eight machines ranging from 2'x3' to 5'x9'. We heat and form plastic sheets over precision molds for enclosures, radomes, and OEM parts with fast lead times.
Hill Plastics delivers precision-engineered plastic enclosures through end-to-end contract manufacturing — from design assistance and low-cost prototyping to high-volume thermoformed production. Serving OEM manufacturers, aerospace, telecommunications, and industrial sectors across the U.S. from our 20,000+ sq. ft. Lewisville, Texas facility, we combine 45+ years of expertise with competitive pricing and fast turnaround.
Comprehensive plastic enclosure manufacturing solutions — from prototype tooling and vacuum forming to precision CNC trimming and high-volume production.
Custom thermoforming and vacuum forming using eight machines ranging from 2'x3' to 5'x9'. We heat and form plastic sheets over precision molds for enclosures, radomes, and OEM parts with fast lead times.
Skilled fabrication services including precision trimming, drilling, heat bending, bonding, riveting, and threaded insert installation — producing finished enclosures and industrial components to exact drawing specifications.
Automated CNC routing and cutting using two 5'x10' trimming centers for accurate, repeatable edge finishing, contour cutting, and assembly-ready part production on thermoformed and fabricated plastic parts.
Custom mold and tooling solutions using aluminum, polyurethane, and CNC-milled wood. Low-cost prototype tooling transitions seamlessly to aluminum production molds after design approval.
Rapid prototypes produced from low-cost wood or polyurethane tooling, typically available within a few weeks. Ideal for design review and fit-and-function evaluation before committing to production tooling.
Engineering support from Brad and Cody Hill to guide tooling design, material selection, and process planning — evaluating durability, chemical resistance, impact requirements, and cost for your application.
Our sales and engineering team — Brad and Cody Hill — work directly with your engineers and purchasing team to review product requirements, define enclosure specifications, and recommend the optimal thermoforming process, materials, and tooling approach for your application.
Discover how Hill Plastics delivers precision enclosures and fabricated parts that meet the toughest OEM and industrial standards.
"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 proven contract manufacturing expertise, industry-grade equipment, and a commitment to quality that engineers and purchasing teams across the U.S. rely on.
Founded in 1977, our team brings decades of plastic enclosure manufacturing knowledge — with staff averaging 20+ years of industry tenure.
Eight thermoforming machines, a high-speed rotary thermoformer, and two 5'x10' CNC trimming centers in over 20,000 sq. ft. of manufacturing space.
From initial design and low-cost prototype tooling to finished, assembly-ready enclosures — we manage every stage so your project stays on budget and on schedule.
Low-cost wood and polyurethane prototype tooling, combined with efficient rotary production, keep enclosure manufacturing costs highly competitive for U.S. OEM manufacturers.
Experienced engineers dedicated to precision plastic enclosure manufacturing.
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 manufactures a wide range of custom plastic enclosures including equipment housings, radome enclosures, industrial enclosures, machine guards, and OEM component enclosures. Parts are produced via thermoforming, vacuum forming, and CNC fabrication using materials such as ABS, HDPE, PETG, KYDEX, and UV-resistant ASA/ABS, tailored to your application's environmental and structural requirements.
Talk to our engineering team for expert guidance and a free project consultation.
Hill Plastics ships precision-manufactured plastic enclosures and fabricated parts to customers across the entire United States.
Nationwide U.S.
Service Area
20,000+ Sq. Ft.
Manufacturing Facility
Mon–Fri 7AM–4:30PM
Business Hours
Contact our Lewisville, TX facility to discuss your contract manufacturing requirements today.
Proven track record since 1977 in plastic enclosure manufacturing.
Industry-standard CAD and CNC interface for precision part production.
Custom quality control system monitoring every production stage for OEM standards.
Share your drawings, design files, or project concept with our engineering team. We'll review your requirements and provide a competitive quote with material and tooling recommendations — typically within a few business days.
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.