Large-Scale Drape Forming | Custom Curved Plastic Fabrication UK & International

Tom Burleigh
Aug 24
2 min read

Updated: 3 days ago

Introduction

Not every plastic fabrication shop can handle complex, curved shapes, especially at scale. That’s where large-format drape forming comes in.

At S&D Solutions, we’re proud to be one of the few UK-based plastic fabricators with the capability to produce large, curved or radiused plastic components using precision drape forming techniques. It’s this service that’s brought us clients across Europe, the USA, and Asia, often for projects others simply can’t deliver.

What is Drape Forming?

Drape forming is a heat-forming technique used to shape plastic sheets over a mould or form without using a vacuum or pressure system.

The plastic is heated to a specific temperature until it becomes pliable, then gently “draped” over the form to take on its shape as it cools.

Unlike vacuum forming, drape forming allows for:

Smoother curves and radii
Larger overall panel sizes
Greater control over thickness and surface finish

Why Large-Scale Matters

Many plastic fabricators can handle small or mid-size parts — but once the panel gets big, most simply don’t have the tooling, ovens, or experience to do it right.

We specialise in large-format drape forming, allowing us to create:

Oversized machine guards with curved edges
Architectural panels for displays or interior features
Enclosures with shaped fronts or lids
Custom forms for transport, aerospace, and specialist equipment

If you need a smooth, formed curve at a size over 1m, we can do it. Many others can’t.

Materials & Finishes

We commonly drape form:

Acrylic (Perspex®) – ideal for transparent guards or displays
PETG – impact-resistant and food-safe
Polycarbonate – high strength and heat-resistant
PVC – for more industrial or structural applications

We’ll advise on the best option for your job — balancing strength, clarity, cost, and compliance.

Who Uses Our Large-Scale Drape Forming?

We’ve delivered projects for:

Medical equipment manufacturers
Industrial machinery producers
Retail and POS designers
Event and exhibition contractors
International suppliers needing UK-based fabrication

Our formed panels have shipped across the UK, Europe, North America and Asia.

Need help with your next project, or your current supplier is not able to handle the large-scale forming requirements you have?

Get in touch and let's chat.

*Large curved polycarbonate panel produced using drape forming at a UK plastic fabrication workshop*

Frequently Asked Questions

What’s the largest size you can drape form?

It depends on the material, thickness, and curve but we regularly form panels up to 2m or more. Contact us with your specs.

Can you form multiple units from one mould?

Yes — we can produce multiple parts from a single tool, ideal for repeat orders or batch runs.

Can you help with design and tooling?

Absolutely. We can assist with CAD design and create basic form tools or jigs in-house.

Is drape forming better than vacuum forming?

For large, gentle curves yes. Drape forming avoids webbing, keeps edges smoother, and works well for transparent panels.