Heavy Gauge Thermoforming Services
Custom heavy-gauge parts for OEMs, formed and 5-axis CNC trimmed in Zanesville, Ohio, in runs of dozens to hundreds.
- Runs of dozens to hundreds
- 5-axis CNC trimming
- Your tool, design or part
- Made in Zanesville, Ohio
Shirley K’s makes heavy gauge thermoformed covers, housings, enclosures, trays, tubs, lids, liners and panels for OEMs. Bring a current tool, tool design, part design or existing part. We recommend the material and thickness for the job.
Custom heavy-gauge parts
Where heavy gauge parts fit
Heavy gauge thermoforming forms thick plastic sheet into durable parts. By common industry convention that means sheet over about 3 mm (0.120 in). The sheet thins as it stretches, so deep areas of the finished part end up thinner than the sheet you start with.
Thermoforming heats a plastic sheet, shapes it over or into a tool, then cools and trims it. Heavy-gauge parts generally become durable product components or reusable handling items. Heavy-gauge work, also called thick gauge thermoforming, makes equipment covers, housings, trays and panels.
Vacuum forming uses a pressure difference to draw heated sheet against a tool. Heavy gauge vacuum forming applies that method to heavier sheet. Depth, corners and shape changes affect how the sheet stretches. Our process guide explains the basics, and heavy vs thin gauge covers how the two differ. For vacuum forming as a service, see custom vacuum forming services.
What we make
- Covers and housings. We make equipment covers and enclosures, including the blue covers on a paper-cushioning packaging machine.
- Instrument case bottoms. We make Kydex case bottoms for handheld radiation survey meters and for medical equipment enclosures. The meter case bottoms are CNC-trimmed and nickel-coated inside for shielding.
- Tubs and lids. We make tubs and lids for extreme-duty material handling.
- Trays and dunnage. We make trays and returnable dunnage for handling parts and materials.
- Custom components. We make plastic components used in the assembly of OEM end products.
How we run your parts
Dozens to hundreds of parts per order is our core work. Quick change-over shuttle machines handle low volumes, and rotary machines run larger volumes. Short-run specialty equipment handles emergency short runs.
We use 5-axis CNC trimming for repeatable trim and hole patterns so parts mate with other components. We also offer assembly, finished-goods inventory programs and drop ship programs. Tell us which you need.
Materials we run
We run ABS for tough, versatile custom parts and enclosures, and Kydex for durable custom parts with a quality finish. We use acrylic for parts needing clarity or specific mechanical properties.
All the HDPE we thermoform is HMW-HDPE. It goes into our food-handling totes and lugs, material-handling totes and returnable dunnage, and into custom parts that take repeated handling. We use HIPS and PETG for organizational and school storage trays. Tell us what the part does so we can recommend material and thickness. We form sheet from .080″ to .450″ thick.
Four ways to start
- Move your current tool. Send the details for a tool transfer. We’ll check the tool’s condition and fit with our equipment.
- Send your tool design. Send your existing tool design to start the project.
- Send your part design. Send a drawing or CAD model showing the part you need.
- Send an existing part. We can reverse engineer a tool from your existing part.
Low-volume OEM parts
Thermoforming tooling is typically single-sided and costs less than an injection mold, making it an option for large parts and short runs. Injection molding often suits complex molded features or volumes that support its tooling cost.
Compare the complete part cost, including forming, trimming and assembly. Our thermoforming versus injection molding guide covers the tradeoffs. We run shorter runs than many other thermoformers.
What to send for a quote
Send what you have and tell us what’s undecided. Our quote preparation guide helps organize the request.
- Drawing or CAD model. Show the shape, mating components, openings and surfaces that matter.
- Sample or tool details. Include a sample part or details about the tool you want to move.
- Use and order quantity. Tell us how you use the part, what impacts or chemicals it faces, and how many you expect to order.
- Other production needs. Tell us if you need assembly, finished-goods inventory or drop shipping.
Our Ohio plant
Our plant is at 1150 Newark Road, Zanesville, OH 43701. Shirley K’s spun out of Fabri-Form in 2013 and is a Certified Service-Disabled Veteran-Owned Small Business. Our parts are proudly manufactured in the USA.
See our Ohio manufacturing page or call (740) 868-8140. You can also send project details to orders@shirleyks.com.
Heavy Gauge Thermoforming Questions
Can you take over an existing tool?
Yes, if it checks out. We check the tool, plan the move with you and your current supplier, and run first articles for your approval.
Can I start without a CAD model?
Yes. We can reverse engineer a tool from an existing part. A drawing or tool details can also start a quote.
Do you handle larger production volumes?
Yes. Dozens to hundreds of parts per order is our core work, and our rotary machines run larger volumes.
How are openings and edges finished?
We use 5-axis CNC trimming for repeatable trim and hole patterns. That helps parts mate with other components.
Can you recommend a material?
Yes. Tell us what the part does and the conditions it faces. We’ll recommend material and thickness.
Send us your heavy-gauge part
A drawing, CAD model, sample part or tool details is enough for a quote.
Call: (740) 868-8140 · Email: orders@shirleyks.com · 1150 Newark Road, Zanesville, OH 43701