Hill Plastics delivers precision-fabricated custom transformer enclosures engineered to your exact specifications. From thermoforming and CNC trimming to full assembly, our 45+ years of expertise and 20,000 sq ft facility ensure enclosures that meet strict dimensional tolerances, protect sensitive electrical components, and hold up across demanding industrial and OEM applications nationwide.
End-to-end fabrication capabilities for custom transformer enclosures, from initial design and prototyping through high-volume production.
Custom fabrication of transformer enclosure housings using CNC trimming, heat bending, bonding, and edge finishing. Parts are produced to exact drawing specifications with precision drilling, fastener installation, and assembly-ready finishing included.
Heavy-gauge vacuum thermoforming of enclosure shells and covers using materials such as ABS, HDPE, and KYDEX. Low-cost tooling and short lead times make this ideal for custom enclosure projects of any production volume.
Automated CNC router trimming and cutting services deliver clean, repeatable enclosure components. Contour cutting, precision drilling, and edge finishing ensure assembly-ready transformer enclosure parts every time.
Custom molds and tooling for transformer enclosure production using aluminum, polyurethane, and wood patterns. Low-cost prototype tooling transitions seamlessly to aluminum production molds after design approval.
Rapid prototypes for transformer enclosure designs produced from low-cost wood or polyurethane tooling. Master patterns are CNC-milled to print specifications, allowing design review and functional evaluation before committing to production tooling.
Scalable production runs from short-run to thousands of units using rotary thermoforming technology that is 2.5x faster than standard machines. All production parts are quality-controlled for appearance and dimensional accuracy.
Our sales and engineering team—Brad Hill and Cody Hill—reviews your transformer enclosure specifications, application environment, and performance requirements. Using SolidWorks CAD software, we assess dimensional tolerances, material fit, and tooling design strategy before any work begins.
See how OEM manufacturers and industrial clients across the U.S. rely on Hill Plastics for precision enclosures.
"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 specialized plastic fabrication expertise, advanced equipment, and a commitment to precision set Hill Plastics apart for every enclosure project.
Founded in 1977, our team brings decades of hands-on enclosure fabrication knowledge that OEM manufacturers and engineers across the U.S. depend on.
Our 20,000 sq ft Lewisville, TX facility houses eight thermoforming machines, two CNC trimming centers, and a 4'x7' rotary thermoformer for high-volume runs.
From SolidWorks CAD design and low-cost prototype tooling to finished enclosure production, we manage every stage so your project stays on budget and schedule.
Low-cost tooling options and high-efficiency rotary thermoforming allow us to deliver quality transformer enclosures competitively across both short and high-volume runs.
Experienced engineers and sales professionals dedicated to your enclosure project 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.
Hill Plastics fabricates transformer enclosures from a range of engineering-grade plastics including ABS, High-Temperature ABS, HDPE, PETG, UV-Resistant ASA/ABS, KYDEX, and Polystyrene. Material selection is guided by your application's requirements for impact resistance, chemical exposure, UV stability, operating temperature, and cost—ensuring the best fit for each enclosure's environment and performance demands.
Talk to our engineering team for expert guidance and a free project consultation.
Established in 1977, over four decades of trusted manufacturing expertise.
Professional CAD design using industry-standard SolidWorks software.
Custom quality control system monitors every production stage for consistency.
Share your project specifications and our engineering team will respond with a tailored recommendation and competitive pricing. We support projects from prototype through high-volume production.
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.