Hill Plastics delivers precision PS and HIPS thermoforming services backed by 45 years of manufacturing excellence. From rapid prototyping to high-volume production, we provide cost-effective custom solutions with expert material selection, low-cost tooling, and CNC-trimmed accuracy. Whether you need medical device housings, industrial enclosures, or custom OEM components, our advanced equipment and experienced team ensure your parts meet exact specifications on time and within budget.
Comprehensive plastic forming solutions from design assistance and rapid prototyping to precision fabrication and high-volume manufacturing.
Precision vacuum forming using eight machines ranging from 2'x3' to 5'x9'. We heat PS and HIPS sheets to precise forming temperatures, then shape them into molds using vacuum pressure for dimensionally accurate, repeatable parts trimmed to your exact specifications.
Advanced automated CNC routing with two 5'x10' trimming centers for primary and secondary operations. We deliver precision-trimmed parts with clean edges, exact drilling, fastener preparation, and assembly-ready finishing for custom enclosures and OEM components.
Low-cost wood or polyurethane tooling enables fast prototype production for design review and function testing. Master patterns are CNC-milled to print specifications, with prototypes often delivered in just weeks for quick iteration and approval.
Expert tooling design using SolidWorks and advanced CNC machinery. We create low-cost wood patterns for prototypes and cast precision aluminum molds for production runs, ensuring dimensional accuracy and ease of design adjustments throughout development.
Scalable capacity from short runs to thousands of parts using our 4'x7' rotary thermoforming machine with cycle times 2.5 times faster than standard equipment. Every production part undergoes quality control for appearance and specification compliance.
Our sales and engineering team assists with product design, material selection, and tooling optimization. We evaluate cost, impact resistance, durability, tensile strength, and environmental requirements to ensure the best PS or HIPS grade for your application.
For over four decades, Hill Plastics has delivered precision-thermoformed polystyrene and high-impact polystyrene components to OEM manufacturers, aerospace firms, medical device companies, and telecommunications leaders nationwide. Our 20,000+ square foot facility houses eight thermoforming machines and advanced CNC trimming centers, enabling us to handle everything from single prototypes to high-volume runs. With low-cost tooling, quick turnaround times, and a commitment to quality control at every stage, we transform your design concepts into finished parts that meet exact dimensional tolerances and performance requirements—all while keeping projects on budget and on schedule.
Partnering with aerospace, telecommunications, and medical device companies nationwide to deliver precision thermoformed solutions.
"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..."
We combine 45 years of manufacturing expertise with cutting-edge equipment and a relentless focus on quality and value.
Since 1977, we've built a reputation for delivering high-quality thermoformed parts with competitive pricing and quick turnarounds.
Our 4'x7' rotary thermoforming machine runs 2.5 times faster than standard equipment, ensuring cost-effective high-volume production without sacrificing precision.
We create affordable wood or polyurethane tooling for fast prototype iterations, helping you validate designs and make adjustments before committing to production molds.
From design assistance and material selection to CNC trimming and assembly, we deliver turnkey solutions backed by quality control at every production stage.
Decades of engineering experience dedicated to your 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.
Polystyrene (PS) is a rigid, cost-effective plastic with excellent clarity and smooth surface finish, ideal for packaging, displays, and low-impact applications. High-Impact Polystyrene (HIPS) is a toughened grade of PS with added rubber polymers, offering significantly improved impact resistance and durability while maintaining good dimensional stability and ease of processing. HIPS is preferred for industrial enclosures, machine guards, and protective housings where mechanical strength is critical. Our team evaluates your application requirements—including impact demands, environmental exposure, and budget—to recommend the optimal material grade for your thermoformed parts.
Connect with our engineering team for expert material selection, tooling design, and rapid prototyping.
Proven track record since 1977
Industry professionals with decades of expertise
Top-rated by clients nationwide
Tell us about your project requirements, and our engineering team will provide expert guidance on materials, tooling, and production timelines.
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.