Thin Gauge Thermoforming

Thin gauge thermoforming is the process of heating and forming thin plastic roll stock sheet into custom packaging for high-volume products. At FormTight, we specialize in in-house thin gauge thermoforming, delivering reliable, repeatable results for food, medical, and retail manufacturers who need consistent, high-performance packaging at scale.

In-House Thin Gauge Thermoforming

FormTight handles all thin gauge thermoforming in-house, allowing for consistent quality and control across large production runs. We work with various thermoformable plastics and can support detailed part geometries, complex cavity designs, and required repeatability.

FormTight’s machinery drives high-volume production, making it ideal for manufacturers with large-scale packaging requirements.

Thin, or light, gauge thermoforming uses thinner plastic roll stock sheet – typically under 0.090” – and is ideal for disposable or single-use packaging.  Most of our thin gauge projects are geared toward high-speed, high-volume production.

In contrast, thick, or heavy, gauge thermoforming uses thicker material that comes in sheets – up to .500” - for durable, structural parts, like enclosures or panels, often with lower run volumes.

FormTight specializes in thin gauge thermoforming for manufacturers who require fast, repeatable, and consistent output at scale.

FormTight partners with food, medical, and retail manufacturers to deliver thermoformed packaging that meets strict industry standards.

From high-quality produce trays for food processors and shipping trays for bakeries, to secure cavity packaging for medical devices, to high-visibility retail clamshells, our in-house capabilities meet the production demands of leading manufacturers across various industries.

Thin gauge vacuum forming offers a cost-effective and scalable way to produce packaging for large product runs.

Some of the key benefits of thin gauge thermoforming include:

- Fast cycle times & efficient material usage

- Compatibility with automated filling and sealing equipment

- Strong visual appeal for retail display

- Flexibility in forming complex geometry and features

When you need dependable packaging that performs consistently, thin gauge vacuum forming may be ideal for you.