Plastic Fabrication Services in Tennessee | Since 1977

Hill Plastics works with a wide range of thermoplastic sheet materials, including ABS, High-Density Polyethylene (HDPE), PETG, High-Temperature ABS, UV-Resistant ASA/ABS, Polystyrene (PS), KYDEX, and decorative foil-laminated materials. Material selection is guided by your application's specific requirements—impact resistance, chemical exposure, temperature range, durability, and cost—to ensure the best-performing and most cost-effective solution for your part.

Thermoforming heats a flat plastic sheet to a pliable temperature, then forms it over or into a mold using vacuum pressure. Unlike injection molding, thermoforming requires significantly lower-cost tooling—often CNC-milled wood for prototypes—and is far more economical for low-to-medium production volumes and large-format parts. It also offers shorter lead times from design to first article, making it ideal for custom enclosures, OEM parts, and industrial components.

Prototype tooling and initial parts can often be completed within a few weeks, depending on design complexity. A wooden master pattern is CNC-milled to your print specifications and mounted on a mold base, after which prototype parts are thermoformed for your review. This low-cost process lets you evaluate fit and function quickly and make design adjustments before committing to production aluminum tooling—saving both time and money.

Yes. Hill Plastics is equipped for everything from single prototypes to high-volume production runs. For high-volume needs, our 4'x7' rotary thermoforming machine operates at 2.5 times the speed of standard single-station machines, enabling cost-effective large-batch output. Our 20,000+ sq. ft. facility, eight thermoforming machines, and two CNC trimming centers provide the capacity to scale production efficiently as your demand grows.

Hill Plastics serves a broad range of industries for customers across Tennessee and the United States, 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, oil and gas, and transportation. Their 45-year track record includes work with major customers such as Southwest Airlines, CommScope, and Pearson Medical.

Hill Plastics operates two 5'x10' CNC trimming centers and uses SolidWorks software for CAD design and CNC interface. Fabrication capabilities include precision contour trimming, edge finishing, precision drilling, fastener preparation, heat bending, bonding, riveting, and threaded insert installation. These operations are applied to thermoformed parts as well as sheet plastic components, delivering assembly-ready parts that meet exact drawing specifications for enclosures, machine guards, and custom OEM components.

Low-cost wood or polyurethane tooling allows you to form physical prototypes for design review and functional testing without the expense of aluminum production molds. Because wood patterns are easy to modify, design changes can be incorporated quickly and affordably before final approval. Once the design is confirmed, the master pattern is used in the aluminum casting process to produce the durable production mold—giving you a streamlined, cost-controlled path from concept to finished part.

Hill Plastics uses a custom quality control system that monitors production progress at every stage, from initial forming through CNC trimming and final finishing. Parts are inspected against print specifications and appearance standards throughout the manufacturing process. With staff averaging over 20 years of industry experience, the team identifies and addresses quality issues proactively, ensuring that every production run—whether a short batch or thousands of units—meets the dimensional accuracy and surface quality standards your application requires.