Thermoforming & Vacuum Forming Services | Plastic Trays, Covers, Panels & Housings

Tom Burleigh
Aug 24
2 min read

Updated: Sep 16

Introduction

When you need shaped plastic components at scale without the cost of full injection moulding, thermoforming and vacuum forming are two of the most efficient and cost-effective options.

At S&D Solutions, we offer both processes in-house, allowing us to create consistent, high-quality parts for clients across a wide range of industries. Whether you need a single tray or a batch of custom housings, we’ve got the tools and experience to deliver.

What’s the Difference Between Thermoforming and Vacuum Forming?

Both processes start the same way: by heating a sheet of plastic until it becomes pliable. The key difference is how the plastic is formed over the mould.

Vacuum Forming
Uses suction to pull the heated plastic over a mould.
Best for shallow or simpler shapes.
Thermoforming
A broader term that includes vacuum forming but can also involve pressure or matched moulds.
Ideal for deeper, more complex shapes or greater detail.

Not sure which one you need? Don’t worry, we’ll guide you.

What We Make With Thermoforming & Vacuum Forming

We commonly use these processes to create:

Protective plastic covers
Trays for medical or industrial use
Shaped panels and enclosures
POS product trays or display elements
Machine housing components

Because the tooling is relatively simple and quick to produce, it’s a great solution for:

✅ Small to mid-sized production runs
✅ Custom-shaped repeat jobs
✅ Clients who need a premium finish without moulding costs

Materials We Work With

We can form a range of thermoplastics depending on your requirements, including:

ABS – tough, durable, and good for structural use
HIPS – great for prototyping or short-run packaging
PETG – clear and food-safe
Polycarbonate – heat-resistant and strong
PVC – versatile and cost-effective

Why Choose S&D Solutions?

In-house tooling and forming for faster turnaround
Experienced team to guide material and method choice
High consistency across repeat parts
UK-based service with flexible volume options
Can combine with CNC trimming and finishing for precise results

Whether you’re replicating a product tray or creating a new enclosure design, we’ll make sure it’s formed right the first time.

*Vacuum-formed plastic tray being removed from the forming machine in a UK fabrication workshop*

Frequently Asked Questions

What’s the best method for deeper shapes?

Thermoforming (with pressure or matched tooling) is better for deeper or more detailed parts.

Can you help with design and prototyping?

Yes — we offer full CAD support and can create prototype parts before full runs.

What’s the turnaround time?

Depends on the complexity, but typically 1–2 weeks from approval of design and tooling.

Is vacuum forming suitable for clear plastics?

Yes — we can vacuum form clear PETG or polycarbonate with great surface quality.