Thermoforming/Vacuum Forming

Lerner Molded Plastics provides custom thermoforming solutions and vacuum forming services for manufacturers across a wide range of industries. Every project is built to customer specifications, from prototype development through full production. Our team supports each stage of the manufacturing process with engineering assistance, in-house tooling, forming, CNC trimming, finishing, assembly, packaging, and logistics. By managing these services under one roof, we help customers simplify production while receiving plastic components that meet their design and performance requirements.

Our custom thermoforming solutions are built to support a wide variety of plastic component applications. Heated plastic sheet is formed over precision tooling to create durable parts used in automotive, medical, industrial, consumer, transportation, aerospace, packaging, and OEM markets. Because every project has different requirements, we work with you to select the right process, material, and production method for your application.

Our capabilities include heavy-gauge and thin-gauge thermoforming, inline production, rotary thermoforming, single-station forming, and twin-sheet vacuum forming. This flexibility allows us to manufacture everything from large structural components to precision plastic parts while supporting both short runs and high-volume production.

We process a variety of thermoplastic materials, including ABS, HDPE, polypropylene, polystyrene, acrylic, polycarbonate, PET, and PETG. Material selection depends on the function, appearance, strength, and environmental demands of your product. We also manufacture parts up to 15 feet long with draw depths up to 3 feet, giving customers greater design flexibility for large-format components.

Customers choose our thermoforming services because they offer several production advantages:

• Lower tooling costs than many alternative manufacturing methods
• Faster tooling and production lead times
• Cost-effective prototype, low-volume, and high-volume production
• Easier design revisions during product development
• Wide selection of thermoplastic materials
• Large-part manufacturing capabilities
• Secondary finishing and assembly services available from one supplier

Whether you’re launching a new product or replacing an existing component, our team delivers thermoforming solutions that align with your production goals and product requirements.

Our vacuum forming services provide an efficient option for producing custom plastic components. During production, a heated plastic sheet is drawn tightly against a mold using vacuum pressure to create consistent, repeatable parts. This process works well for many applications, including equipment covers, machine guards, trays, housings, retail displays, packaging components, and automotive parts.

Every vacuum formed part we manufacture is custom. We do not produce standard, off-the-shelf products. Instead, we build each component around your drawings, performance requirements, and production volume. Our vacuum forming services support prototype projects, low-volume production, and ongoing manufacturing, giving customers the flexibility to scale production as demand changes.

Vacuum forming offers lower tooling costs than many other manufacturing methods, along with quicker tooling production, reduced material waste, and simpler design updates when product changes are needed.

Beyond forming, we provide CNC trimming and a full range of secondary operations to help move your project from production to delivery. These services include drilling, ultrasonic welding, hot stamping, pad printing, painting, labeling, barcoding, assembly, packaging, warehousing, inventory management, and distribution. Working with a single manufacturing partner helps reduce coordination between multiple suppliers while keeping your project moving efficiently.

Quality is built into every custom project from the beginning of production through final delivery. Our manufacturing team follows established production procedures and uses precision tooling, advanced forming equipment, and CNC trimming technology to produce consistent plastic components that meet customer specifications.

Close communication remains an important part of every project. We review application requirements, production goals, and finishing needs before manufacturing begins so each part is produced according to the approved design. Final finishing, assembly, packaging, and logistics services are completed with the same focus on consistency and dependable delivery.

If you’re looking for a manufacturing partner that offers custom thermoforming solutions and vacuum forming services, Lerner Molded Plastics is ready to support your project from concept through production. Whether you need prototype parts, large production runs, or complete manufacturing support, our team has the experience and capabilities to help you move forward. Contact us today to discuss your project and learn how our custom plastic forming services can support your production requirements.