Custom Thermoforming & Vacuum Forming Services
Plastic Components for OEMs & Commercial Production
American Plastic Supply manufactures thermoformed plastic trays, housings, covers, and equipment components for manufacturers and commercial customers.
We work with engineering and purchasing teams on commercial prototypes, production batches, and repeat orders from our Clearwater, Florida facility.
Parts We Manufacture
Custom Trays & Inserts
Formed trays for organizing, separating, and supporting tools, components, and products during assembly, handling, or transport.
Housings & Enclosures
Plastic shells and housings designed around your equipment’s geometry, mounting requirements, and appearance.
Covers & Guards
Formed covers, shrouds, and guards made to your specifications for machinery and commercial equipment.
Equipment Components
Custom panels, liners, inserts, and other formed parts incorporated into your finished products or used in your operations.
Thermoforming Capabilities
We review your part geometry, material requirements, and order quantities to determine a practical approach to tooling, forming, and finishing.
| Capability | Details |
|---|---|
| Forming capacity | 36" x 48" forming area |
| Material thickness | 1/16" - 3/8" |
| Materials | ABS, HDPE, Kydex, Boltaron, PETG, Polypropylene, PVC |
| Tooling | Tooling requirements quoted based on part geometry, material, and expected production volume |
Explore our Vacuum Forming Guide for Engineers & Buyers
Essential Thermoforming Design Rules
- Draft Angles: Minimum 2° to 3° for female molds and 3° to 5° for male molds to ensure clean part release.
- Radii & Fillets: Avoid sharp corners. Use a minimum radius of 1.5 mm (1/16") to prevent severe material thinning.
- Draw Ratios: Keep the depth-to-width ratio within 3:1 to maintain uniform material distribution.
- Wall Thickness: Anticipate variation; material naturally thins out at the deepest points and corners of the part.
- Undercuts: Limit or avoid undercuts. Shallow undercuts require specialized articulating mold features or secondary trimming.
- Tolerances: Design for standard tolerances of ± 0.020" to ± 0.030" for the first inch.
File Types We Can Work With
We can quote from common CAD files, drawings, and images, including:
- DXF
- DWG
- STEP / STP
- AI / EPS
- SVG
- JPG / PNG for reference
- Other common design files
Clean CAD files generally lead to faster quoting and better results, but we can also work from drawings, sketches, or existing parts in many cases.
From Prototype Through Production
1. Review Your Requirements
Send your CAD files or drawings, intended application, material requirements, and quantities. We review the design and discuss considerations that may affect tooling, fit, appearance, and cost.
2. Define Tooling & Sample Requirements
We establish the tooling scope and any sample requirements as part of the quote. Critical features and acceptance criteria should be agreed upon before tooling and production begin.
3. Evaluate Initial Parts
For new tooling, agree on a sample review process before releasing the production run. This gives your team an opportunity to assess fit, function, and appearance.
4. Schedule Production & Repeat Orders
Once requirements are approved, we coordinate production and finishing around the agreed order. Share expected annual usage and release quantities so we can discuss repeat-order needs.
Project Example: Custom Trays
Custom thermoformed trays provide organized locations for tools inside protective cases. Each tray’s layout is developed around the tools it holds and the available space within the case.
Application: Tool organization inside protective cases
Material: Utility Grade Black ABS
Scope: Confirm design, make mold, send first article, product repeat parts
Production: Orders of 100-400 parts at a time
