Thin Gauge Thermoforming

At Innova, we specialize in automated in-line thermoforming of thin to medium-gauge parts—formed, trimmed, and stacked in one seamless process.

Thin Gauge Thermoforming for Scalable Production

At Innova Engineered Plastics, our fully automated, roll-fed in-line thermoforming systems are built for high-volume production of thin to medium gauge parts. This process is ideal for applications like consumer packaging, medical device trays, procedure sets, clamshells, tubs, skin pack sets, transport trays and technical components that demand repeatability and high-volume production. We can also utilize our thin gauge thermoforming systems in a clean room environment for sensitive applications.

No matter what kind of parts you’re manufacturing, you need a process that delivers precise, high-quality results that meet all of your requirements. When you partner with Innova to engineer and manufacture your plastic components, you get more than just a simple solution. Our integrated forming, trimming, and stacking system streamlines every step of production with additional secondary operations and assembly services available. From concept to final part, we collaborate with you to optimize your products for manufacturability (DFMA) to streamline production and meet production needs. With a focus on accuracy and quality, our in-line thermoforming services are tailored to meet the needs of fast-paced, quality-driven industries.

Learn more about our process below or contact our team to see if thin gauge thermoforming is the right choice for your project.

Check out our case studies for more information

In-Line Thermoforming Part
In-Line Thermoforming Part

ADVANTAGES OF THIN GAUGE THERMOFORMING

Thin gauge thermoforming is preferred for producing thin to medium-thickness parts quickly and consistently. When you need high production volumes, fast turnaround times, or a more cost-effective process, our in-line thermoforming systems are the solution you’re looking for.

  • Faster Production Speeds: this system integrates extrusion, heating, forming and trimming into one continuous process
  • High Volume Efficiency: capable of producing thousands of parts per hour with low scrap rates
  • Lower Material Costs: utilizes roll-fed plastic, which is more cost-effective than pre-extruded sheets and scrap is easy recycled back into the process, reducing waste
  • Consistent Part Quality: sheets are formed immediately after extrusion, ensuring precise temperature control, leading to uniform parts
  • Integrated Trimming: automated trimming stations produce finished parts that are ready for packaging or secondary operations

size capabilities

With advanced in-line thermoforming capabilities, we produce components with precision, efficiency, and scalability. Whether you’re developing detailed designs or high-volume part runs, our process delivers consistent, high-quality results.

  • Can manufacture components up to 23″ (L) x 20″ (W) x 4.5″ (D)

Thin Gauge Thermoforming Part
Thin Gauge Thermoforming Material

materials of construction

If you need assistance, we can help with material selection from our comprehensive list of typical plastics below. Whether you’re looking for a cost-effective solution or need a plastic that meets strict requirements, we will find the option that fits your project requirements. If you would like to request custom or additional materials, we are happy to discuss those options with you.

  • PET
  • PETG
  • RPET
  • Polycarbonate
  • Polypropylene
  • HDPE
  • Polystyrene
  • Polyurethane (TPU)