Thermoforming & Vacuum Forming
Custom thermoforming and vacuum forming services using eight machines ranging from 2'x3' to 5'x9'. We form ABS, HDPE, PETG, KYDEX, and more into precision parts for enclosures, trays, radomes, and OEM components.
From custom thermoforming and vacuum forming to CNC trimming and full fabrication, Hill Plastics delivers precision plastic parts engineered to exact specifications. Based near Dallas/DFW and serving manufacturers nationwide, we support every stage from prototype to high-volume production — with competitive pricing, low-cost tooling, and over 45 years of proven expertise.
Comprehensive plastic manufacturing solutions — from design and prototyping to high-volume production — built to your exact specifications.
Custom thermoforming and vacuum forming services using eight machines ranging from 2'x3' to 5'x9'. We form ABS, HDPE, PETG, KYDEX, and more into precision parts for enclosures, trays, radomes, and OEM components.
Full-service fabrication including precision trimming, CNC machining, heat bending, bonding, fastener installation, and edge finishing — producing custom enclosures, machine guards, POP displays, and industrial parts to drawing specs.
Advanced automated CNC router equipment and two 5'x10' trimming centers deliver accurate, repeatable contour cutting, precision drilling, and edge finishing for thermoformed and fabricated plastic components.
Custom molds from wood, polyurethane, or aluminum tailored to your design. We guide you from low-cost prototype tooling through production-grade aluminum molds, with CNC-milled master patterns and full design support.
Rapid prototypes from low-cost wood or polyurethane tooling, typically ready within weeks. Ideal for design review or functional evaluation before committing to full production tooling and runs.
Our 4'x7' rotary thermoforming machine runs 2.5x faster than standard single-station equipment, enabling cost-effective, quality-controlled high-volume production from thousands of parts with competitive pricing.
Our sales and engineering team — Brad and Cody Hill — work directly with your engineers and purchasing agents to review your product requirements, drawings, and application needs. We evaluate material options, tolerances, and design function to set the right foundation.
See how manufacturers, OEMs, and engineers across the country rely on Hill Plastics for precision results.
"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 trusted precision plastics partner for OEMs, engineers, and manufacturers across the United States.
Founded in 1977 near Dallas/DFW, our decades of hands-on experience mean reliable results for even the most demanding plastic manufacturing applications.
From design consultation and low-cost prototyping to high-volume thermoforming and CNC fabrication — everything under one roof in Lewisville, TX.
Wood and polyurethane prototype tooling keeps your early-stage costs low, with a clear path to aluminum production molds once your design is approved.
Serving OEM manufacturers, aerospace, telecommunications, medical, marine, and industrial customers across the entire United States with competitive pricing and quick turnaround.
Experienced engineers and sales professionals dedicated to your precision plastic project.
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.
Precision plastics are manufactured through processes like thermoforming, vacuum forming, and CNC fabrication. At Hill Plastics, plastic sheets are heated to a forming temperature and shaped over a mold using vacuum pressure, then CNC-trimmed to exact drawing specifications. Additional operations such as drilling, bonding, heat bending, and fastener installation are applied as needed to produce assembly-ready parts.
Talk to our engineering team for a free consultation on your precision plastic parts needs.
Hill Plastics ships precision plastic parts and components to OEM manufacturers and businesses across the entire United States.
Nationwide USA
Service Area
20,000+ Sq. Ft.
Facility Size
1977
In Business Since
We supply precision plastic parts to customers across the United States — contact us to discuss your project.
Proven precision plastics expertise since 1977
Advanced SolidWorks design and CNC interface capability
Industrial-grade manufacturing capacity for any production volume
Share your project requirements and our engineering team will respond with material recommendations, tooling options, and a competitive quote — 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.