Your Questions, Answered.

We process 10+ thermoplastic materials in-house, including ABS, ASA, Polycarbonate (Lexan), HIPS, PETG, HDPE, PP, Kydex, PMMA (Acrylic), and PLA. We extrude our own sheets from raw pellets, giving us full control over thickness, color, and material properties. We also work with specialty grades like FR (flame retardant), UV-stabilized, and ESD-safe variants.

Our vacuum forming machines accommodate parts up to 2500mm x 1500mm (approximately 8 ft x 5 ft). Sheet thickness ranges from 0.5mm to 12mm. For larger assemblies, we can form multiple sections and join them using adhesive bonding or ultrasonic welding.

We serve 15+ industries worldwide, including wind energy (nacelle covers, blade root fairings), commercial vehicles (body panels, fenders), electric vehicles (battery covers, body panels), HVAC (duct covers, housings), agriculture (tractor canopies), mobile robots & AGVs, drones & UAVs, refrigeration & appliances, medical devices, mass transit, and more.

Yes. We export to the USA, Canada, Europe, the Middle East, and across Asia. Our facility in Gujarat, India is strategically located near Nhava Sheva (JNPT) port. We handle export documentation, containerized shipping, and work with freight forwarders to deliver door-to-port or door-to-door.

For new projects: tooling takes 2–4 weeks, with first article samples within 1 week after tooling approval. Production runs typically ship within 2–3 weeks depending on volume. For repeat orders with existing tooling, lead times are 1–2 weeks. Rush orders can be accommodated on a case-by-case basis.

We are flexible on MOQs. For new tooling projects, we typically start with a pilot run of 50–100 pieces. For repeat production, we can handle orders from 100 to 10,000+ pieces per month. Our sweet spot is 500–5,000 parts per month, but we scale up or down based on your needs.

Yes — we are vertically integrated. We extrude our own thermoplastic sheets from raw pellets using our in-house extrusion lines. This gives us control over sheet thickness (0.5–12mm), color, surface finish, and material properties. It also reduces lead times and costs compared to buying pre-made sheets.

After forming, we provide 5-axis CNC router trimming for precision edges, adhesive bonding and ultrasonic welding for multi-part assemblies, hardware insertion (threaded inserts, brackets), painting and texturing, silk screening, and final packaging. We deliver fully finished, ready-to-install parts.

You can submit an RFQ through our contact form on the website, email us at [email protected], or call us at +91 82912 96791. For the fastest response, include a 2D drawing or 3D CAD file (STEP, IGES, or DXF), desired material, estimated annual volume, and any special requirements. We typically respond within 24–48 hours with a detailed quotation.

Absolutely. Our engineering team reviews every project for thermoforming feasibility and provides DFM feedback — including draft angles, undercuts, wall thickness uniformity, and material selection. We also offer a free DFM Checklist guide that you can download from our website.

We maintain an 8-stage quality control process covering incoming material inspection, sheet thickness verification, forming parameter monitoring, dimensional checks, visual inspection, functional testing, packaging audit, and final sign-off. Our QC team uses CMM machines, calipers, and go/no-go gauges for dimensional verification.

Vacuum forming uses atmospheric pressure (~14.7 psi) to draw a heated sheet onto a mold, making it ideal for large parts with moderate detail. Pressure forming adds compressed air (up to 60–80 psi) on the non-mold side, producing sharper detail, tighter radii, and better surface definition — often rivaling injection molding aesthetics at a fraction of the tooling cost. We use pressure forming for parts requiring textured surfaces, crisp logos, or tight tolerances like medical device enclosures and kiosk housings.

Co-extrusion is a process where two or more layers of different plastic materials are simultaneously extruded through a single die to form a multi-layer sheet. For example, an ABS/PMMA co-extruded sheet combines the structural strength of ABS with the UV stability, gloss, and scratch resistance of PMMA on the surface. This is widely used for automotive exterior panels, outdoor enclosures, and any application requiring both durability and a high-quality surface finish. Our in-house extrusion lines produce co-extruded sheets tailored to your application.

After a part is thermoformed, it needs to be trimmed to its final dimensions. CNC (Computer Numerical Control) router trimming uses a 5-axis robotic milling machine to cut precise edges, holes, and features into the formed part. This delivers repeatable accuracy (±0.5mm typical), clean edges without burrs, and the ability to cut complex 3D profiles. We use CNC trimming on virtually all production parts to ensure consistent quality and tight tolerances.

Flame retardant grades are thermoplastic materials formulated to resist ignition and slow the spread of fire. Common FR grades include FR-ABS (UL94 V-0 rated), FR-HIPS, and FR-Polycarbonate. They are required for applications in mass transit (railway interiors, bus panels), medical devices, electrical enclosures, and any environment where fire safety standards must be met. We stock and extrude FR grades in-house and can advise on the right rating for your application.

Standard thermoforming tolerances are ±0.5mm to ±1.5mm depending on part size, material, and geometry. For pressure-formed parts with matched tooling, we can achieve tighter tolerances approaching ±0.3mm. Factors affecting tolerance include sheet thickness variation, draw ratio, material shrinkage, and ambient temperature. Our CNC trimming step ensures that critical dimensions and hole locations are held to tighter tolerances than the forming process alone can achieve.

Thermoforming molds are typically made from aluminum (most common for production), composite/epoxy (for prototyping and short runs), or temperature-controlled cast aluminum (for high-volume precision work). Unlike injection molding which requires hardened steel molds costing $50,000–$500,000+, thermoforming molds typically cost $2,000–$25,000 and can be produced in 2–4 weeks. We design and manufacture our tooling in-house, which reduces lead time and gives us full control over mold quality.

Yes. We offer 6 standard surface textures (T01 through T06) ranging from high-gloss smooth to deep matte grain. Textures are applied during the sheet extrusion process, so they are integral to the material — not a coating that can wear off. Custom textures can also be achieved through textured mold surfaces. Textured parts are popular for automotive interiors, medical device housings, and industrial enclosures where fingerprint resistance and a premium feel are important.

HDT measures a material's resistance to deformation under load at elevated temperatures. A higher HDT means the part can withstand more heat without warping. For example, standard ABS has an HDT of ~95°C, while Polycarbonate (Lexan) reaches ~130°C. This is critical for parts exposed to direct sunlight (automotive, outdoor enclosures), engine compartments, or industrial environments with elevated operating temperatures. We help you select the right material based on your thermal requirements.

ESC is the brittle fracture of a plastic part when exposed to certain chemicals under mechanical stress — even chemicals that wouldn't normally attack the material. Common culprits include adhesives, sealants, cleaning solvents, and lubricants. We prevent ESC through careful material selection (e.g., ASA and PMMA-capped grades have excellent ESC resistance), proper design (avoiding sharp internal corners that concentrate stress), and compatibility testing with chemicals the part will encounter in service.

Thermoforming offers several advantages over FRP for large parts: faster cycle times (minutes vs. hours), no hazardous styrene emissions, lighter weight (20–30% typical), consistent wall thickness, better surface finish without gel-coat, and full recyclability. FRP may still be preferred for very low volumes (<50 parts) or parts requiring extreme structural rigidity. Many of our customers have successfully switched from FRP to thermoformed ABS or ASA, reducing costs by 30–50% while improving quality and lead times.

Yes, but with some design considerations. Simple undercuts can be achieved using collapsible cores or split molds. For more complex geometries, we form two separate shells and join them using adhesive bonding or ultrasonic welding — this is our standard approach for parts like ducted enclosures, hollow housings, and structural panels. Our engineering team can advise on the best approach during the DFM review stage.

The orange peel effect is a surface defect where the formed part develops an uneven, wavy texture resembling orange skin. It's caused by uneven heating, excessive draw ratio, or using a material that's not suited for the geometry. We prevent it through precise zone-controlled heating (our IR quartz heater ovens have individually controllable elements), proper material selection (PMMA-capped sheets resist orange peel), and optimized forming parameters developed through our 25+ years of process experience.

Yes. Ultrasonic welding uses high-frequency vibrations to create a molecular bond between two thermoplastic parts without adhesives, screws, or solvents. It produces strong, hermetic seals and is ideal for joining two thermoformed shells into a single enclosed structure. We use ultrasonic welding extensively for HVAC ducting, equipment enclosures, and structural panels where a clean, permanent bond is required.

PPAP (Production Part Approval Process) is a standardized quality framework used in automotive and aerospace to ensure that a supplier can consistently reproduce parts meeting all design specifications. It includes documentation such as FMEA (Failure Mode and Effects Analysis), control plans, dimensional reports, and material certifications. We support PPAP submissions for OEM customers and can provide the full documentation package required for production approval.

Yes. Formpack manufactures thermoformed radomes — radar-transparent covers used in aerospace, defense, and telecommunications. We use materials like ASA, ABS, and PETG that allow RF signal transmission while providing structural protection. Our vacuum forming and pressure forming processes produce radomes for UAVs, ground-based radar systems, satellite communication equipment, and weather stations. CNC trimming ensures precise mounting interfaces.

Yes. We manufacture thermoformed body covers, chassis panels, sensor housings, and bumper shells for autonomous mobile robots (AMRs) and automated guided vehicles (AGVs). Materials include ABS for impact resistance and polycarbonate for sensor windows. Our process delivers lightweight, durable covers that protect electronics and sensors while maintaining a clean industrial aesthetic.

Yes. Formpack manufactures fire retardant thermoformed covers for solar plant inverters and power electronics using PC-FR (fire retardant polycarbonate). We can produce XL-size covers for large string inverters and central inverters. PC-FR meets UL94 V-0 fire ratings, providing both fire safety and impact protection for outdoor solar installations.

Yes. We produce battery covers and enclosures in PC-FR (fire retardant polycarbonate) for electric vehicles, energy storage systems, and industrial battery packs. PC-FR provides fire resistance (UL94 V-0), high impact strength, and electrical insulation — all critical for battery safety. We handle the complete process from sheet extrusion to CNC-trimmed, assembled covers.

Yes. We manufacture thermoformed suction ducts for textile machinery, including fiber collection ducts, lint extraction channels, and air handling components. Materials include ABS, HIPS, and ASA depending on operating temperature and chemical exposure. Our in-house extrusion allows custom sheet thickness and our CNC trimming ensures precise duct dimensions for proper airflow.

Yes. Formpack manufactures ESD (electrostatic discharge) trays using ESD-grade HIPS and ABS materials with surface resistivity of 10^4 to 10^11 ohms. These trays are used for semiconductor wafer handling, PCB transport, electronic component carriers, and cleanroom applications. We can produce custom pocket configurations for specific component geometries.

Yes. We manufacture thermoformed medical stent packaging in PETG — a material chosen for its optical clarity, chemical resistance, and sterilizability (EtO and gamma compatible). Custom trays, blisters, and clamshells are produced with precise pocket dimensions to securely hold stents and other medical devices during storage and transport.

Yes. Formpack manufactures thermoformed parts for electric buses including exterior body panels, interior wall cladding, ceiling panels, dashboard components, battery covers (in fire retardant PC-FR), seat backs, and luggage rack panels. We work with EV bus manufacturers in India and internationally, providing lightweight alternatives to metal and FRP panels.

Yes. We manufacture custom thermoformed ducts and enclosures for industrial machinery including ventilation ducts, cable management channels, wire harness ducts, equipment guards, and machine covers. Materials range from ABS and HIPS for indoor use to ASA for outdoor or UV-exposed applications. Twin-sheet forming is available for hollow structural ducts.

Yes. Formpack exports thermoformed parts to the USA, Canada, Europe, the Middle East, and across Asia. We have a dedicated North America program with a New York-based contact. Our facility near Nhava Sheva (JNPT) port in Gujarat enables efficient container shipping worldwide. We handle export documentation, crating, and logistics.