Filed Under:
Manufacturing
Published on
April 30, 2025
Thermoforming is a highly versatile plastic manufacturing process widely used for creating semi-rugged to ruggedly durable, customized plastic products. At Royal Case Company, we employ thermoforming processes to produce precise, high-quality case interiors and components specifically tailored to the needs of a specific product.
In this blog, we'll provide an overview of thermoforming, its essential steps, and its significance in the production of versatile plastic solutions.
Thermoforming involves several critical steps:
Heating – Heated plastic sheets until soft and flexible.
Forming – The heated plastic is shaped by vacuum forming or applying air pressure to a mold shaped in the desired form of the final product.
Cooling – The formed plastic is cooled into a solid to maintain the desired shape.
Trimming and Finishing – Excess material is trimmed, and the product is finished according to specifications.
Thermoforming is adaptable, making it ideal for producing detailed, precise, and cost-effective plastic products, like the rigid thermoformed panels on our collection of EVA cases. Royal Case primarily uses this method to make intricate case inserts that help organize and hold products within the case, but we also use it for other components based on customer need. We frequently work with thin-gauge thermoforming when creating lightweight packaging solutions that require precision without added weight.
This process provides numerous advantages:
Cost Efficiency – Economical for both small and large production runs due to low tooling costs. The main cost is in the mold, but it can be used over the lifetime of production.
Versatility in Design – Allows production of intricate shapes, precise details, and varied thicknesses depending on product use requirement and characteristics.
Fast Production – Shorter lead times and quicker cycles compared to other forming processes. This is especially true if a mold already exists.
High-Quality Finish – Produces aesthetically pleasing products with excellent surface finishes. In cases requiring more durability and structural strength, thick-gauge thermoforming is often the preferred method.
Thermoforming serves multiple industries:
Packaging Industry – Customized packaging solutions, including food packaging, trays, clamshells, and blister packs to house a variety of products in and out of cases.
Medical Sector – Sterile packaging, medical trays, and equipment housings. In some cases (pardon the joke), it's used for the medical device itself, depending on the use needs.
Automotive Industry – Interior and exterior vehicle components that require precise detailing and abnormal shapes.
Consumer Goods – Displays, protective covers, and customized product cases.
Thermoforming is an essential manufacturing process that’s precise and comes with cost-effectiveness while offering design versatility. Royal Case Company specializes in custom thermoformed product case interiors and component solutions tailored to your specific requirements. Contact us today to learn more!
