What Is Thermoforming?
When you hold a sturdy plastic tray or custom packaging insert, there’s a good chance it was made using thermoforming. But what is thermoforming, exactly?
Let’s break it down.
💡 What Is Thermoforming at Custom Tray?
Thermoforming is a manufacturing process where a plastic sheet or roll is heated until it’s pliable, then formed over a mold using a vacuum, and finally trimmed into a finished part. It’s commonly used to make trays, clamshells, lids, and custom packaging for industries like:
Automotive
Electronics
Food & Beverage
Cosmetics
Medical Devices
Because it’s cost-effective and fast, thermoforming is a go-to solution for companies that need protective, lightweight, and custom-fit packaging.
🛠️ How Does Thermoforming Work?
The process has a few key steps:
Material Selection
A plastic sheet (like PET, PVC, or ABS) is chosen based on your product's needs—ESD protection, food safety, impact resistance, etc.Heating
The sheet is heated to a temperature where it becomes flexible—but not melted.Forming
The sheet is then pulled over (or into) a custom mold using vacuum & this creates the exact shape needed for your part or product.Cooling & Trimming
Once cooled, the formed plastic is trimmed to remove excess material and finish the final design.
✅ Why Choose Thermoforming with Custom Tray?
Custom Fit: Perfect for securing delicate or irregular-shaped items
Cost-Effective: Ideal for mid-to-high volume production
Fast Turnaround: Faster than injection molding for many projects
Sustainable Options: Many thermoformed materials are recyclable or made from recycled content
👀 Real-World Example: Automotive ESD Tray
Let’s say an automotive supplier needs a tray to hold printed circuit boards (PCBs) with static-sensitive components. A custom ESD thermoformed tray can protect these parts during shipping—keeping them secure, shielded from static, and perfectly aligned for automation or assembly.
💬 Ready to Learn More or Get a Quote?
At Custom Tray, we specialize in creating custom thermoformed packaging solutions that are functional, durable, and tailored to your needs. Reach out to us today to talk design, lead times, and get started.