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Thermoforming
Applications
From radomes and aerospace parts to EV battery covers and medical stent packaging — Formpack manufactures precision thermoformed components for 18 industries from our 150,000 sq ft vertically integrated facility in Gujarat, India. We extrude the sheet, form the part, trim it, and ship it worldwide.
Dedicated Application Pages
Explore detailed case studies, material recommendations, and engineering specifications for our most requested thermoforming applications.
Wind Energy
Large-format thermoformed components for wind turbine nacelles, blade root fairings, and interior cladding. UV-stable ASA and impact-resistant ABS ensure decades of outdoor performance.
Commercial Vehicles
Thermoformed body panels, fenders, bumpers, and interior trim for trucks, buses, and commercial fleets. Lightweight alternatives to sheet metal with faster tooling turnaround.
Electric Vehicles & EV Bus Parts
Thermoformed EV components including fire-retardant battery covers in PC-FR, lightweight body panels, and interior cladding for electric buses and scooters. Serving India's growing EV ecosystem.
Drones, UAVs & Radome Manufacturing
Precision thermoformed drone components and radomes for defence and commercial UAVs. RF-transparent PETG and PC radomes, lightweight fuselage shells, and ruggedized sensor housings.
Medical Enclosures & Stent Packaging
Thermoformed medical device enclosures, diagnostic equipment covers, and precision PETG stent packaging trays. Cleanroom-compatible processes with full traceability for healthcare applications.
Industrial Machine Covers & HVAC Ducts
Custom thermoformed machine covers, industrial HVAC housings, textile machine suction ducts, and equipment guards. From single prototypes to production runs of 10,000+ parts.
Aerospace & Defence Parts
Thermoformed aerospace components including RF-transparent radomes, fire-rated Kydex interior panels, precision ducting, and ruggedised equipment enclosures for defence and aviation applications.
Autonomous Mobile Robots & AGV Covers
Thermoformed body covers and sensor housings for autonomous mobile robots (AMRs), automated guided vehicles (AGVs), and warehouse robots. Lightweight, impact-resistant shells for the robotics industry.
More Industries We Serve
Beyond our featured applications, Formpack provides thermoforming solutions for construction equipment, robotics, transit, electronics, solar energy, agriculture, retail, food packaging, and more.
Off-Highway & Construction Equipment
ABS · ASA · HIPS
Rugged thermoformed components for tractors, excavators, and construction equipment. UV-stable ASA for outdoor durability, impact-resistant ABS for operator safety.
Golf Carts & Low-Speed Vehicles
ABS · ASA
Complete thermoformed body panel sets for golf carts and low-speed electric vehicles. UV-resistant ASA for outdoor use, colour-matched finishes, and rapid tooling for custom designs.
Refrigeration & Appliances
HIPS · ABS
High-volume thermoformed inner liners for refrigerators, freezer compartments, and appliance panels. HIPS for cost efficiency, ABS for premium finishes.
Mass Transit & Railway
ABS · Kydex
Fire-rated thermoformed interior panels for buses, metro coaches, and railway carriages. Kydex and fire-retardant ABS meet stringent transit fire safety standards.
Electronics & ESD Trays
HIPS-ESD · ABS-ESD
Precision thermoformed ESD-safe trays and packaging for semiconductors, PCBs, and electronic components. Conductive and dissipative materials prevent electrostatic damage during transit and storage.
Solar & Renewable Energy
PC-FR · ABS FR V-0 · ASA
Fire-retardant thermoformed covers for solar inverters, combiner boxes, junction boxes, and battery storage systems. PC-FR material meets UL 94 V-0 flammability ratings for solar plant installations.
Luggage & Travel
ABS · PC
Thermoformed hard-shell luggage, trolley cases, and protective equipment cases. Twin-sheet forming for hollow structures, textured finishes, and custom branding.
Hydroponics & Agriculture
HIPS · HDPE · PP
Cost-effective thermoformed grow trays, seedling trays, and hydroponic system components. UV-stabilised materials for greenhouse and outdoor agricultural applications.
Retail & POP Displays
HIPS · PMMA · PETG
Eye-catching thermoformed retail displays, point-of-purchase stands, and branded kiosks. Crystal-clear PETG and PMMA for premium visual impact.
Food Packaging
HIPS · PET · PETG · PLA
Food-grade thermoformed packaging including clamshells, meal trays, and blister packs. FDA-compliant materials with options for biodegradable PLA.
Signage & Lighting
PMMA · PC · PETG
Thermoformed light diffusers, illuminated sign faces, and LED covers. Optical-grade PMMA and PC for uniform light transmission and weather resistance.
Materials by Application
Choosing the right thermoplastic is critical. Here is a quick reference of materials we extrude in-house and the applications they serve.
| Material | Key Properties | Best For |
|---|---|---|
| ABS | Impact resistance, paintability, rigidity | Machine covers, vehicle panels, medical enclosures |
| ASA | UV stability, weatherability, colour retention | Wind energy, outdoor covers, automotive trim |
| PC / Lexan | Optical clarity, high-heat, impact strength | Radomes, lighting, battery covers |
| PC-FR | Fire retardant (UL94 V-0), self-extinguishing | EV battery covers, solar inverter covers |
| PETG | Crystal clarity, chemical resistance, FDA-safe | Medical stent packaging, retail displays, food trays |
| HIPS | Low cost, easy forming, good detail | Fridge liners, ESD trays, packaging |
| Kydex | Fire-rated, self-extinguishing, durable | Aircraft interiors, mass transit panels |
| PMMA | Optical clarity, scratch resistance, gloss | Signage, lighting diffusers, vehicle trim |
Vertically Integrated Process
Every part is manufactured under one roof — from raw pellet to finished, trimmed, and assembled component. No outsourcing, no delays.
Sheet Extrusion
In-house extrusion of ABS, HIPS, ASA, PC, PETG, and more in custom colours and gauges.
Vacuum Forming
Single-station and rotary forming with XL capacity for large parts like nacelle covers and bus panels.
CNC Trimming
5-axis CNC routers for precision trimming, drilling, and edge finishing to tight tolerances.
Assembly & QC
Bonding, fastener installation, painting, and final inspection before worldwide shipping.
Shipping Thermoformed Parts Worldwide
From our facility in Gujarat, India, we export thermoformed components to over 20 countries. Our vertically integrated model — from pellet to finished part — means competitive pricing, fast turnaround, and consistent quality for global OEMs.
Have a Part to Convert?
Send us your drawing, CAD file, or even a rough sketch — our engineers will evaluate feasibility, recommend materials, and provide a no-obligation quote.