Thick Gauge Thermoforming
When you need durable plastic parts fast, thick gauge thermoforming delivers. FormTight specializes in thick gauge thermoforming as a cost-effective solution for producing long-lasting, high-impact plastic parts at scale. We handle everything from low to high-volume runs for manufacturers who need reliable parts without the delays or complexity of injection molding.
Skip the high tooling costs and avoid the long lead times. Get production-ready parts without the complexity.
Custom Forming Solutions for Durable Applications
FormTight partners with OEMs who need more than prototypes; they need production-ready parts that perform. Thick gauge thermoforming is ideal for creating strong, functional components built to withstand demanding use. Our thick gauge process transforms rigid plastic sheets into structural components designed for industrial environments.
Using precise heat and vacuum pressure, we create custom shapes that balance design flexibility with consistent strength. Every part is engineered to withstand real-world conditions without compromise.
Common applications include:
- Medical: Equipment housings, diagnostic enclosures, surgical device covers
- Electronics: Control panels, component housings, protective enclosures
- Transportation: Interior/exterior vehicle components, transport fixtures
- Retail: Display fixtures, protective trays, transport pallets
- Aftermarket: Replacement panels, custom guards, modified equipment housings
Thick Gauge Thermoforming Capabilities
- Max Sheet Size: 53” x 101”
- Materials: ABS, PETG, HDPE, and more
- Equipment: Triple stage rotary + 4 single station machines
With in-house tooling and 5-axis CNC trimming under one roof, FormTight eliminates delays while maintaining repeatability. We handle a wide range of projects, from multi-part assemblies and formed details to built-in mounting features.
Thick Gauge Thermoforming vs Injection Molding: Making the Right Choice
Not every project needs injection molding's complexity. Thick gauge thermoforming excels when you need:
- Lower tooling investment: Tooling costs 50-90% less than injection molds
- Faster time to market: 2-4 week tooling lead times vs. 12-16 weeks
- Large part production: Economical for parts over 12" without size constraints
- Design flexibility: Modify tooling quickly for design iterations
- Variable wall thickness: Create needed strength without uniform walls
PETG and HIPS - Domes
PETG - Custom Thick Gauge Product
Thick Clear
Thick Black and Clear
ABS - Custom Thick Gauge Tray
Start Your Next Thick Gauge Thermoforming Project
Ready for a thermoforming partner that can handle thick or heavy gauge thermoforming parts at production scale? FormTight is experienced in working with manufacturers who need reliable turnaround, tight tolerances, and zero nonsense.
Tell us about your project, and we’ll show you what’s possible. Request your custom quote today.
Thick Gauge Thermoforming FAQs
What is your minimum order size?
We typically work with orders anywhere from 10 units to 5,000 units or more.
What's your typical lead time from order to delivery?
Most projects ship within 4-6 weeks from tooling approval, depending on volume and complexity.
Can you help with tooling design?
Yes, we offer in-house tooling support to streamline production and reduce delays.
What materials do you use for thick gauge thermoforming?
We work with ABS, polycarbonate, HDPE, and other performance-grade plastics. Check out our materials page to learn more.
What wall thicknesses can you achieve?
We work with sheet thicknesses from .020” to .500”, with the ability to create variable wall thickness through careful forming control.