The thermoforming process

Your project begins with an initial meeting, during which we discuss your needs — size, special characteristics, and the fit of your product in its packaging. You receive an estimate that includes prototyping, tooling costs, and production costs for a variety of quantities and materials.

Design. Our designers then generate a computer design to your specifications.

Product with CAD design (in background)

Prototyping. We make a CNC-machined prototype. For this we employ a resin-based prototyping material, a highly compressed polymer composite foam called REN Shape™. The resulting prototype is dimensionally stable enough to provide thermoformed samples, yet also easy to modify. Often the prototypes can be made and samples provided to the customer in one week or less. In emergency situations we have supplied prototypes in one to two days. We provide prototype samples in a variety of materials and thicknesses for your evaluation.

REN prototype ready for sampling

Preliminary machine sampling. With your approval, we create a sample cutting die to generate machined samples that are even closer to your final product. These samples allow us to make changes before generating the actual production tooling.

Sample die is checked for accuracy

Production sampling. We create production molds that are CNC-machined aluminum that’s been polished and Teflon coated when necessary. Again, you’ll approve production samples for final approval before we run your project. At this stage we also begin to build any necessary sealing tools so that we can deliver your product and sealing tool in the shortest possible time frame.

Multi-cavity (9 up) tray with fine detail

Production. Typically, your job runs within two to three weeks of receiving your purchase order.

Production line

Assembly, packing, and sealing. We can provide assembly, product packing, and sealing when you need it. We offer both heat and radio frequency (RF) sealing.

Warehousing. Because of our large (26,000 square feet) warehouse, we’re able to keep a wide variety of stock on hand to provide you with fast turnaround. We can also help you manage your just-in-time needs by storing your product here, ready to ship.

Raw material on hand