plastic fabrication services

Vacuum Forming

Plastic vacuum forming is one of the most important types of thermoforming processes.  We employee vacuum forming for low volume and bulk production of plastic parts. Efficiency and affordability are two factors that make plastic sheet vacuum forming a popular process among plastic OEMs. Although most steps of this process are automated and conducted using molds and computer aided devices, experience matters a lot. Ehren-Haus is one of the leading providers of custom plastic forming services in South Carolina. We can provide highly customized plastic parts in a wide range of materials at a fraction of the cost of other forming methods. Ehren-Haus has in-house tool, pattern and mold making which assures the fastest turnaround times in the industry.

Vacuum thermoforming is a process where the plastic sheet is heated to a typical thermoforming temperature, where it becomes flexible, yet retains its durability. The sheet is then placed on a male or female mold, and completely vacuum sucked to remove any air between the sheet and mold. The vacuum formed sheet is cooled after removing from the mold. Next, cooled vacuum formed sheet is trimmed to form a perfect shape. During the process, if male mold is used then the sheet is placed over it, and if female mold is used then the sheet is placed inside it.

Plastic Vacuum Forming Services Capabilities

Our facility is equipped with a wide range of vacuum and thermoforming equipment. This combined with our engineering expertise makes us one of the leading plastic sheet forming services in the country. Being one of the well-experienced plastic forming service providers, we employ various types of molding process and vacuum forming techniques to form plastic molded parts.

Billow Plug Assist

This technique is employed when female mold is used. The sheet after heating is firmly placed over the female cavity and air is blown into it upwards. The air forms a bubble which helps stretch the material evenly. The bubbles height can be easily controlled using an electric eye. The plug falls into the bubble, and when it hits the lowest position, the sheet is formed by drawing vacuum to the mold.


This technique is used to produce deep draw products of uniform wall thickness.


It is a specialized forming technique, which is employed to create plastic components with a gentle curve or shape.

Air Assist

In this technique, air pressure is employed to pre-form the sheet before it is removed finally.

Secondary Processes

We use 3- or 5-axis CNC routing to trim the vacuum formed parts into a better shape. In addition to this, we also provide in-house mold making, labelling, and gluing services.

Plug Assist

This one of the thermoforming techniques, where the heated polymer sheet is pre-stretched prior to vacuum or pressure application.

Part Sizes

Our access to the latest technology and advanced engineering expertise allow us to create custom shapes of the largest size 48″ x 96″ and sizes as small as 1″x2″.

Types of Materials We Work with

We can provide vacuum formed parts built using the following materials:


We widely use vacuum forming on acrylic sheets. Acrylic is popular with our industrial clients owing to its properties such as transparency, high dimensional stability, and durability.

ABS Plastic

We regularly perform ABS plastic vacuum forming services for our clients across industries. ABS is an abbreviation of Acrylonitrile Butadiene Styrene, and this thermoplastic polymer is known for its excellent machinability, flexibility, customization properties, excellent impact and chemical properties.


Our PVC vacuum forming services are widely utilized for creating parts such as medical trays, shower trays, and bath tubs. Polyvinyl chloride or PVC, as it is commonly known, offers excellent moisture, water, chemical and abrasion resistance. It is used in every industry to make certain parts.


HDPE stands for High Density Poly Ethylene, which is one of the widely used plastics. We perform HDPE sheet vacuum forming for creating various types of durable and lightweight parts. HDPE is strong, lightweight, impact resistant, and can easily resist mildew, mold, and so on.


It is a transparent material well-known for its glass transmission properties. This material is also known for its excellent thermal resistance. We perform vacuum forming of polycarbonate sheets to produce curved and large pieces such as windows and windshields.


This is a thermoplastic that assures excellent durability, chemical resistance, and high strength. Polyethylene terephthalate glycol or PETG is widely used for making containers for storing oil or water, and is also used for medical device manufacturing. You can get in touch with our team today to know more about our PETG sheets vacuum forming services.

In addition to this we also work with a wide range of clear plastic materials. You can best utilize our clear plastic vacuum forming services to produce aesthetically appealing and durable parts.


Applications of Vacuum Thermoforming

We provide custom plastic forming services:

  • Product Packaging

  • Lift Truck Enclosures

  • Equipment Covers

  • Agricultural Equipment

  • Automotive Components

  • Windows and Windshields

  • Exterior Panels

  • Shipping Racks

  • Consoles

  • Electrical Enclosures

  • Belt Guards

  • Interior Panels

  • Domes

  • Bezels

  • Chutes

Benefits of Vacuum Forming Plastic Sheets

There are several benefits of plastic vacuum forming services and the following pointers will help you understand it better.



Vacuum forming is quite unlike other plastic manufacturing processes, as it enables creating intricate designs on the part. Model designations, logos, or texts can be easily vacuum formed on the surface of the parts. Also, the tools that are used to create plastic parts can be easily modified to produce different versions of the same part.

Aesthetically Appealing

This technique is used to produce deep draw products of uniform wall thickness.


Plastic vacuum forming is a one-sided process, which means the finished part will be detailed only on one side. This requires less tooling, which makes it affordable than other plastic manufacturing techniques such as plastic injection molding, blow molding, and rotational molding.

Reliability and Flexibility

Impact resistant thermoplastics are usually considered for vacuum forming, which is why the parts have high resilience and flexibility. Most plastic materials that we work with can withstand moisture, chemicals, and high impacts.

Rapid Product Development

As the process requires less tooling, it enables rapid product development. We regularly process low to mid volumes of vacuum formed plastic parts at our facility.

Why Choose Ehren-Haus for Vacuum Forming Plastic Sheets?

Ehren-Haus is not only one of the many plastic forming services in South Carolina, but we also have built a client base across the country. The following reasons make us popular with our clients.


All plastic fabrication is performed at our large 28, 160 sq. feet facility in Fort Mill, South Carolina. This facility is well connected to other states through air, rail, and sea.


The facility is equipped with various types of vacuum formers, as well as finishing and trimming tools such as trimmers, heated knives, and punch presses, among others.


We employ advanced quality control processes, which help us meet our client requirements and serve them beyond their expectations.


Transparency makes us one of the unique plastic sheet forming service providers. We inform clients at every stage of manufacturing and assist them from designing to production to shipping.


We assure utmost customer satisfaction, by serving them in all possible ways we can.

In addition to custom plastic forming services in South Carolina, we also provide a wide range of custom plastic fabrication services including thermoforming, CNC routing and machining, line bending, trimming, drilling, and tapping and so on. For more information, you can get in touch with our team today.

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