Custom Thermoforming

Thick-Gauge • Twin-Sheet • Engineered Plastic Parts

Custom thermoforming is a plastic manufacturing process that allows you to create larger plastic parts with a much lower tooling cost than other plastic processes.

Thermoformed products can be formed from the same plastics, so there is no need to compromise on physical properties. Thermoformed sheets can be made with high-impact and flame-retardant properties in an infinite range of colors.

Versa 3 delivers custom thermoforming for large, durable plastic parts used in demanding industrial environments.
Our team is often brought in when programs need:

Lower tooling investment than injection molding
Larger or complex part geometries
Structural strength and durability
Rapid prototyping before production tooling

Great for industries like:

Automotive
Mobility
Energy systems
Industrial equipment
OEM programs

Built for Custom Programs

Large parts. Lower tooling cost. Same engineering plastics.

Impact Resistant

Flame Retardant

Environment & Chemical Resistant

Antistatic and ESD Safe

(Surface Resistivity 10³–10⁹ Ω)

Custom Colors, Textures,
and Thicknesses

Thick-Gauge Thermoforming

Equipment housings and enclosures
Machine guards and safety barriers
Large industrial shells and panels
Structural trays and heavy-duty pallets

Twin-Sheet Thermoforming

Automotive and industrial packaging systems
Industrial panels or structural shells
Structural pallets and containers
Large covers with internal reinforcement or air channels

Plastic Pressure Forming

Pressure forming is an advanced process where plastic sheets are shaped using vacuum and pressure for more detailed designs. It builds on vacuum forming, adding pressure to create parts with sharper, more precise details.

Single-Molded Components
Double-Shot Molded Components

Sample Components

Not sure which approach fits your part?

Vacuum Thermoforming in Action

Vacuum forming is a simple way to shape plastic. It works by heating the plastic, then using suction to pull it over a mold. It’s extremely versatile and works great for everything from packaging to custom parts.

Materials Chosen for Performance

PP– Lightweight, chemical resistant, fatigue resistant
PC– High impact strength and heat resistance
HDPE– Durable, chemical and cold resistant
ABS– Impact resistant, widely used
PMMA– Optical clarity and weather resistance
HIPS– Cost effective and easy to form
PVC – Rigid and impact resistant

Prototyping Reduces Program Risk

Confirm fit, function, and performance before scaling.

Large-part thermoforming experience

Engineering input before tooling

Prototyping available

Global manufacturing capability

Clear, realistic guidance

Quality Certifications to Meet Industry Standards

Versa 3 provides comprehensive support throughout the entire manufacturing process. From prototyping to delivery, each customer is assigned a dedicated support team. And we are certified to ensure that your unique industry standards are met.

China

ISO 9001
IATF 16949

India

ISO 9001
IATF 16949

Mexico

ISO 9001
IATF 16949

Bulgaria

ISO 9001

USA

ISO 9001

Thailand

ISO 9001 & 13485 / IATF 16949 / AS9100 / ISO Class 7 & 8 Clean Room

Your Strategic Partner for Innovation

With a proven track record in collaborating with OEM manufacturers and tier 1 and 2 automotive suppliers, we seamlessly operate within global supply chains.

Thick-Gauge • Twin-Sheet • Engineered Plastic Parts

Built for Custom Programs