Large Part Thermoforming Services
AdvancTEK specializes in large part thermoforming and vacuum forming for industries ranging from automotive and medical devices to telecommunications and agricultural equipment. With 35+ years of experience and ISO-certified processes, we deliver cost-effective, highly customizable solutions with shorter lead times than traditional manufacturing methods.
How Large Part Thermoforming Works
AdvancTEK utilizes both rotary and shuttle machines to support our large part thermoforming. Our process ensures precision and repeatability at every stage:
The sheet is introduced into a clamp frame that holds the material sheet in place. The material is then introduced to the oven and heated up to precise processing temperature. Once the material is at the ideal temperature it is automatically removed from the oven and introduced to the forming station and form mold.
In standard thermoforming, the mold utilizes vacuum to force the material to match the geometry of the mold. AdvancTEK also utilizes pressure forming along with vacuum to improve part geometry and improve the surface finish of the finished part.
Why Choose Thermoforming for Large Parts?
Thermoforming offers distinct advantages over other manufacturing methods, especially for large-scale components:
- Cost-effective tooling
- Shorter lead times
- Highly customizable
- Endless possibilities for color and texture
These benefits translate to faster time-to-market and lower upfront investment, making thermoforming ideal for both prototype development and full production runs.
Accommodating Your Largest Projects: Our Thermoforming Capabilities
AdvancTEK’s facility is equipped to handle substantial part dimensions with precision and consistency:
- Sheet sizes up to 6′ to 8′
- Material thickness from 0.0625″ up to 0.5″
Part thickness can range between 0.06″ to 0.5″ thick. With large part thermoforming part thickness is a key variable in ensuring a strong part. Depth of draw is an important factor when determining nominal sheet size. Our experienced engineering team will work with you to optimize part design for structural integrity while meeting your dimensional requirements
Industries & Applications We Serve
Diverse Solutions Across Multiple Sectors
Our large scale vacuum forming and thermoforming capabilities serve a wide range of industries and applications:
Automotive & Recreational Vehicles
- Hoods, roofs, fenders, headliners, skid plates, shields, door panels
- Other interior and exterior plastics for UTVs, ATVs, LSVs, and golf carts
Industrial & Commercial
- Medical device housings
- Construction and agricultural equipment
- Telecommunication antenna housings
- Security towers
- Electronic enclosures
Specialized Applications
- Material/parcel handling
- Energy storage and battery systems
- Marine components
- Warehouse automation
- Consumer/sporting goods – cases, covers, and enclosures
Material Selection for Large Part Thermoforming
Our material selection process is collaborative – we’ll help you identify the optimal material based on your part’s functional requirements, environmental conditions, and aesthetic needs.
Material Options Include:
- ABS (Acrylonitrile Butadiene Styrene)
- HDPE (High-Density Polyethylene)
- TPO (Thermoplastic Polyolefin)
- Co-extruded sheet materials
- Vinyl capped materials
- Utility grade materials for non-cosmetic applications
The typical materials we utilize in large part thermoforming include ABS, HDPE, and TPO.
Depending upon your part requirements, we can also evaluate other materials and finishes to help reduce part costs. Materials can be co-extruded sheet, vinyl capped materials, and utility grade materials for non-cosmetic parts.
Secondary Processing
Beyond large scale vacuum forming and thermoforming, AdvancTEK offers comprehensive secondary processes to deliver finished, ready-to-install components:
- Precision CNC Trimming – AdvancTEK has multiple CNC’s to trim parts to specification and tolerance repeatably. Form tooling is paired with trim fixtures to ensure that quality parts can be produced consistently and safely. We use vacuum to hold parts in place and ensure a clean trim edge.
- Assembly & Finishing Services – AdvancTEK offers many types of value add to complement our large part thermoforming. Assembly, plastic welding, bonding, heat stake welding, ultrasonic are some of the assembly processes we offer that pair well with our thermoforming capabilities.
- Production Support – We also offer sequencing and kitting to support your manufacturing production line.
This integrated approach reduces your supply chain complexity, shortens lead times, and ensures consistent quality from raw material to finished assembly.
Why Partner With AdvancTEK?
When you choose AdvancTEK for large part thermoforming, you’re partnering with an industry leader committed to quality, innovation, and customer success.
Our Differentiators:
- Certified quality – Our team hold ISO 9001:2015, IATF 16949:2016, and ISO 14001 certifications
- Comprehensive capabilities – We offer a wide range of process capabilities and material options
- Proven experience – 35+ years in precision thermoforming
- Engineering support – Our team provides design assistance, material selection guidance, and process optimization to ensure your project’s success from concept to production.
- Expert reshoring help – AdvancTEK is your destination for reshoring your plastic manufacturing operations, including large part thermoforming. We have facilities in Saltillo, MX and Concord, NC to bring your supply chains closer to home. Reshoring is the best way to reduce bottlenecks and improve product quality, so
Ready to Get Started?
Whether you’re developing a new product or looking to optimize an existing manufacturing process, AdvancTEK has the expertise, equipment, and certifications to deliver exceptional solutions.
Get in touch with our team today to get started!