Thermoforming Services in California | Since 1977

Thermoforming is a manufacturing process where thermoplastic sheets are heated to a pliable forming temperature, then shaped over a mold using vacuum pressure. At Hill Plastics, we heat materials like ABS, PETG, or HDPE and draw them tightly over precision CNC-milled molds, removing air between the material and the mold surface. Once cooled, parts are CNC-trimmed to exact specifications. This method is ideal for producing custom enclosures, radomes, and industrial components with excellent dimensional accuracy and surface finish.

We thermoform a wide range of thermoplastics tailored to your application: ABS for impact resistance, PETG for clarity and chemical resistance, HDPE for durability, high-temperature ABS for heat-intensive environments, UV-resistant ASA/ABS for outdoor use, KYDEX for rigidity, polystyrene for cost-effectiveness, and decorative foil-laminated materials for aesthetic finishes. Our team evaluates tensile strength, environmental exposure, and cost to recommend the optimal material for your project, ensuring performance and longevity.

Prototypes can typically be produced in just a few weeks, depending on design complexity. We create low-cost master patterns from CNC-milled wood or polyurethane, which serve as the mold for initial prototypes. This rapid tooling approach allows you to evaluate fit, form, and function quickly. If design adjustments are needed, changes to the wood pattern are straightforward and fast, minimizing delays before moving to production tooling and full-scale manufacturing.

We serve aerospace and aviation, telecommunications, medical devices and healthcare, industrial equipment and OEM manufacturers, defense and military, point-of-purchase and retail display, marine, electronics and electrical equipment, oil and gas, and transportation and logistics. Our versatility stems from 45 years of experience, advanced equipment, and a skilled team capable of meeting stringent industry standards—from FAA compliance in aerospace to FDA requirements in medical device manufacturing.

Vacuum forming typically uses thinner plastic sheets (up to 0.125 inches) for applications like packaging, display trays, and lightweight enclosures. Heavy gauge thermoforming involves thicker materials (0.125 inches and above) and is suited for durable, structural parts like industrial enclosures, machine guards, and aerospace components. Hill Plastics offers both processes across eight machines (2'x3' to 5'x9'), ensuring we can handle projects requiring fine detail or robust, high-strength parts.

Cost depends on part size, complexity, material choice, and production volume. Thermoforming is generally more cost-effective than injection molding for medium to large parts and lower production volumes due to lower tooling costs. We use low-cost wood or polyurethane tooling for prototypes (versus expensive steel molds), and our efficient CNC trimming and fabrication processes minimize labor costs. Contact us with your specifications for a detailed quote tailored to your budget and timeline.

Absolutely. Our 20,000 square foot facility houses eight thermoforming machines, including a 4'x7' rotary thermoforming system with cycle times 2.5 times faster than standard single-station machines. This equipment supports high-volume production while maintaining rigorous quality control for appearance and dimensional accuracy. Whether you need hundreds or thousands of parts, we have the capacity, experience, and competitive pricing to meet your production demands on schedule.

We provide comprehensive secondary operations in-house: precision CNC trimming and cutting, drilling and fastener installation, heat bending for custom angles, bonding and assembly, riveting, threaded insert installation, and edge finishing. Our two 5'x10' CNC trimming centers ensure parts are finished to exact drawing specifications. This integrated approach reduces lead times and costs by eliminating the need for multiple vendors, delivering assembly-ready components directly to you.