What is Thermoforming?

Thermoforming , or “Compression Molding” is a manufacturing process that uses heat to mold flexible fabrics, films, and foams into specific shapes. This technique is particularly beneficial for producing items like:

• AED & Defibrillator Carrying Cases
• Weapons or Instrument Holsters
• Shoulder and Lumbar Support Pad Assemblies
• Device Pouches
• Compartment Liners and Dividers
• Auto Interiors
• Custom Motorcycle Saddlebags
• Many Other Applications (Not Listed)

At Polo Custom Products, we offer both domestic and import capabilities for custom thermoformed products. This unique offering allows us to meet high-volume production needs while maintaining quality and efficiency. No matter the size of your order, we’ve got you covered.

Common Examples of Thermoformed Products

• Packaging
• Protective Cases
• Automotive Parts
• Consumer Products
• Medical Devices
• Signage
• Home Goods
• Industrial Components
• Retail Displays

The Benefits of Thermoforming

Thermoformed Products provide an extra layer of protection for sensitive instruments. Their semi-rigid structure safeguards against:

• Impact
• Dust
• Moisture
• Sun Exposure
• Other Environmental Factors

This added protection is crucial, especially in sectors like medical and government, where sterilization and safety are critical. Unlike flexible, sewn products, thermoformed products offer a smooth, contoured, and wrinkle-free appearance, keeping your products in top condition.

If you need more protection for your product, contact us below to find the right thermoformed solution!

Where Thermoformed Cases Aren’t Required

In addition to thermoforming, we offer industrial sewn products. We specialize in designing and manufacturing critical-function products, such as:

• Ventricular Assist Devices
• Custom Sewn Carrying Bags and Belt Pouch Assemblies
• SCBA Shoulder and Lumbar Support/Harness Assemblies
• Chemical Protective Patient Wraps for the U.S. Department of Defense

Customization and Versatility

Our thermoforming process allows for the creation of custom shapes tailored to your components. We can also integrate die-cut foam or molded plastic inserts for added protection. Features such as dedicated instrument cavities can be incorporated directly into the product design, ensuring your equipment remains secure and well-organized.

Thermoformed products are lightweight, easy to transport, and often have lower tooling costs compared to blow-molded or injection-molded options, making them a cost-effective choice for many industries.

Polo For Your Thermoforming Manufacturing Needs

We’ve acquired Foam Following Function, the original patent holder for our manufacturing process, which sets us apart in the industry. Our engineering and product development capabilities are unparalleled among thermoformed product manufacturers worldwide. With domestic thermoforming capabilities, we can deliver prototypes faster and accommodate lower & higher volume production runs more efficiently than overseas manufacturers.

Click below to see how our expertise can benefit your project!

The Thermoforming Process

1. Foam Lamination: Foams, typically EVA or cross-linked polyethylene, are laminated to fabrics before molding.
2. Material Selection: We use flexible, pliable fabrics that can withstand flame lamination, with mat’ls with some stretch often working best.
3. Depth of Draw:  The depth of draw is limited by the surface area and material stretch. We’ve successfully created products with depths up to 8 inches.
4. Mold Design: Our tooling design can accommodate various shapes and patterns to fit your needs. This separates us from other manufacturers in the thermoforming space.
5. Tolling Costs: Pricing depends on size and surface area, with options available to fit different budgets.

Foam Options for Thermoforming

• EVA (Ethylene Vinyl Acetate): Standard and cost-effective with a range of thickness
• AEPE (Acetate Expandable Polyethylene): High hardness and tensile strength but significantly more expensive
• XPE (Crosslinked Polyethylene): Offers a softer feel, ideal for cushioning applications
• PE Board: Laminated to materials like foams, but limited in shape and more expensive than EVA.

Printing and Labeling Options

Polo printing capabilities produce graphics that withstand wear and tear better than traditional labels, contributing to the longevity of the product's appearance. With fewer separate labeling processes, waste is reduced, making production more sustainable.

We offer various branding solutions for your products, including:

• Debossed/Embossed Logos
• PVC Sew-On Label
• Silkscreen Printing
• Embroidery on Exterior Material
• Woven Labels
• Heat Transfers

Let’s Create Together

If your product requires superior protection and a cost-effective solution, Polo Custom Products is here to help. Our team of experts is ready to design and manufacture a custom solution tailored to your specific needs. We are a one stop shop manufacturing solution that prides itself on Deigning Quality, Engineering Expertise and Manufacturing Perfection.

Contact us or Request a Quote today to learn more about how our Thermoforming capabilities can elevate your product offerings and enhance your brand’s presence in the market!

In addition to our thermoforming capabilities Polo Custom Products has the ability to design and procure non-core components. Examples include injection molded or blow molded trays and tubs, metal stamped brackets, CNC machined parts, specialty packaging and others.