CUSTOM PARTS > THERMOFORMING

CUSTOM THERMOFORMING SOLUTIONS
FOR OEM APPLICATIONS

Gemstar’s custom thermoforming solutions give OEM manufacturers a precise, cost-effective path to complex plastic parts. Lower
tooling costs than injection molding, tighter surface definition than most alternatives, and a manufacturing partner who handles
design, production, and assembly all under one roof.

For OEM, construction, heavy machinery, material handling, and industrial industries we build thermoformed parts that perform in
the field and hold up over time.

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Custom thermoforming for OEM, industrial, and commercial applications

Lower tooling costs than injection molding

Parts delivered fully assembled and ready to install

Made in Cannon Falls, Minnesota

ADDITIONAL ADVANTAGES OF THERMOFORMING

WHAT IS THERMOFORMING IN PLASTIC MANUFACTURING?

Thermoforming is a plastic manufacturing process in which a flat sheet of plastic is heated until malleable, then stretched over a mold and cooled to form the finished part. The process uses a thermoforming machine to apply controlled heat and pressure, producing parts with precise surface definition and complex geometry from a single sheet of material.

Thermoforming is well-suited for parts that require tight detail on the mold-side surface, deep-draw geometry, or negative-draft features that other processes cannot consistently produce. It is an efficient option for mid-volume OEM production where tooling costs need to stay manageable without sacrificing part quality.

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THE COST ADVANTAGE

TOOLING COSTS A FRACTION OF INJECTION MOLDING

For OEM manufacturers producing 500 to 10,000 parts, thermoforming delivers a cost per part and tooling investment that fits the program, without the high upfront investment injection molding requires.

Thermoforming Tooling $2k - $50k Mid-volume viable without high upfront spend
VS
Injection Molding Tooling $20k - $150k High upfront investment required

Ideal for OEM programs producing 500-10,000 parts.

ADDITIONAL ADVANTAGES OF THERMOFORMING

Thermoformed plastic components resist corrosion without coatings, will not permanently dent under impact the way metal does, and come in lighter, reducing mechanical strain on motors and making equipment easier to operate.

CORROSION RESISTANT

Resists corrosion without coatings, so there's no recurring finish maintenance.

IMPACT DURABLE

Will not permanently dent under impact the way metal does.

LIGHTWEIGHT

Lighter components reduce mechanical strain and make equipment easier to operate.

For OEMs in agriculture, construction, material handling, and heavy equipment, that combination of durability and weight reduction matters as much as the cost.

ADDITIONAL ADVANTAGES OF THERMOFORMING

CUSTOM THERMOFORMING CAPABILITIES FOR PLASTIC PARTS

Gemstar’s thermoforming process supports a wide range of design and engineering requirements for OEM programs.

  • Low and deep draw parts with consistent wall distribution
  • Negative draft details for complex part geometry
  • Precise surface definition and sharp feature reproduction
  • Multi-piece assembly part sets produced and assembled as matched components
  • Custom colors and surface textures

ADDITIONAL ADVANTAGES OF THERMOFORMING

THERMOFORMING MATERIALS AND PERFORMANCE OPTIONS

Material selection determines how a thermoformed part performs in its application. Gemstar works with four primary materials, each suited to different performance and application requirements.

  • Polyethylene: cost-effective, excellent impact resistance, high strength, UV stable with material stabilizers, good chemical resistance
  • Acrylonitrile Butadiene Styrene (ABS): quick cycle times, good overall strength and durability, heat and temperature resistance, UL flame retardant versions available
  • Polycarbonate: high impact performance, weather resistant, transparent options available for applications requiring natural light transmission
  • Thermoplastic Polyolefin (TPO): high impact strength, good formability, UV and weather resistance, widely used in powersports applications

LET'S TALK MATERIAL SELECTION

COMMON APPLICATIONS

OEM equipment housings and panels

Industrial material handling parts and enclosures

Metal-to-plastic conversions where weight reduction and cost efficiency are priorities

Powersports and recreational vehicle components

Food service and commercial equipment components

THERMOFORMING APPLICATIONS ACROSS OEM AND INDUSTRIAL INDUSTRIES

Gemstar's custom thermoformed parts serve manufacturers across a wide range of industries and applications.

ADDITIONAL ADVANTAGES OF THERMOFORMINGFEATURED CASE STUDY

DOUGLAS MACHINE: ABS THERMOFORMED FOOD PACKAGING COMPONENTS

When Douglas Machine needed thermoformed ABS components for a food packaging machine, the design called for tight angle tolerances that standard tooling could not consistently hold. The challenge was compounded by the natural tendency of thermoformed material to flex back toward its original flat sheet position after machining.

Gemstar’s engineering team developed innovative modular tooling construction that solved the problem, delivering parts with tighter tolerances than industry standard and consistent quality across the production run.

READ THE CASE STUDY

THERMOFORMING IN ACTION

WHY OEMS ARE RETHINKING METAL IN FAVOR OF PLASTIC

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8 TIPS TO CONSIDER WHEN SWITCHING PARTS SUPPLIERS

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THERMOFORMING DESIGN GUIDELINES

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FAQS

What is thermoforming?
Thermoforming is a plastic manufacturing process that heats a flat plastic sheet until it's pliable, then forms it over a mold using vacuum, mechanical pressure, or both. Once cooled, the part holds the shape of the mold and is trimmed to its final dimensions. It's the right process for parts that need precise surface definition, deep-draw geometry, or negative-draft features that other processes can't consistently produce. Thick-gauge thermoforming, which is Gemstar's specialty, uses heavier sheet stock to produce structural OEM parts for food service equipment, industrial material handling, powersports, and other demanding applications.
What is a thermoforming machine?
A thermoforming machine is the equipment used to heat, form, and cool thermoplastic sheets into finished parts. The basic machine includes a heating station that warms the sheet to forming temperature, a clamping frame that holds the sheet in place, a vacuum or pressure system that draws or pushes the softened sheet over the mold, and a cooling stage that locks in the final part geometry. Different machine types fit different parts. Vacuum forming machines use atmospheric pressure to pull the sheet onto the mold, while pressure forming machines add compressed air for sharper detail and tighter feature reproduction. Thick-gauge thermoforming machines, like those running in Gemstar's Cannon Falls, Minnesota facility, are built to handle heavier sheet stock for structural OEM parts.
How does thermoforming work?
Thermoforming works in four stages: heat, form, cool, and trim. A flat plastic sheet is loaded into the machine and clamped in a frame, then passed through a heating station until it reaches forming temperature. Once pliable, the sheet is drawn or pressed over a mold using vacuum, pressure, or both, taking on the exact geometry of the tool. The part cools and solidifies on the mold, then moves to a trim station where excess material is removed and the part is finished to customer specifications. The full cycle typically runs in minutes rather than hours, which is part of what makes thermoforming well-suited to mid-volume EAUs of 500 to 10,000 parts.
What are the advantages of thermoforming?
Thermoforming delivers a combination of structural performance, design flexibility, and cost efficiency that fits mid-volume OEM production. Compared to injection molding, thermoforming offers significantly lower tooling costs, quicker upfront lead times, and greater flexibility to accommodate design changes. Compared to metal components, thermoformed plastic parts resist corrosion without coatings, will not permanently dent under impact, and are much lighter. This can reduce mechanical strain on motors and make equipment easier to operate. For OEMs in food service, material handling, powersports, and heavy equipment, that combination of durability, weight reduction, and cost makes thermoforming a strong candidate for both new programs and metal-to-plastic conversions.
How much does thermoforming cost?
Thermoforming costs break into two categories: tooling and per-part pricing. Tooling for thick-gauge thermoforming typically runs $2,000 to $50,000 depending on part size, geometry, and mold material. Per-part pricing depends on sheet material, part dimensions, secondary operations like trimming and assembly, and total annual volume. For most mid-volume OEM applications running 500 to 10,000 parts a year, thermoforming delivers a lower total cost than injection molding once tooling and per-part pricing are combined, while staying competitive with metal fabrication on weight and corrosion resistance. Gemstar's engineering team can provide an accurate quote once we understand part geometry, material, volume, and specifications.
What is a thermoformed part?
A thermoformed part is any plastic component manufactured by heating a sheet of thermoplastic and forming it over a mold. Common thermoformed parts include food service and commercial equipment components (e.g. refrigerator and freezer liners), industrial material handling parts and enclosures, powersports and recreational vehicle components(e.g. UTV hoods and body panels), OEM equipment housings and panels, structural panels, machine guards, and protective covers. Thick-gauge thermoformed parts, which are Gemstar's specialty, are used in applications that demand structural strength, dimensional accuracy, and long service life. Many start as metal-to-plastic conversions, where OEMs replace heavier or more expensive metal and fiberglass components with thermoformed plastic to reduce cost and weight without sacrificing performance.

READY TO TALK ABOUT YOUR PART?

Whether you are evaluating thermoforming for a new design, working through a metal-to-plastic conversion, or looking for a more capable manufacturing partner, Gemstar's engineering team is ready to help.

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