Scroll Down to View Applications of Plastic Thermoforming!
In our gallery below, we illustrate a variety of plastic thermoforming applications. To begin, we show you examples of how plastic thermoforming might be a great fit for your project. Next, we might explain why vacuum forming could be a better fit for your project than, for example, pressure forming. Or, maybe we would recommend our Technical twin sheet thermoforming process to help with a project that requires additional strength. Most of all, we are here to help steer you in the right direction to achieve a perfect end product.
Plastic Thermoforming Offers Many Benefits
We bring a variety of potential benefits to your project with the thermoforming process. To begin, we offer potentially significant savings in tooling costs, especially as parts get larger. Additionally, we do not introduce stress into this process, unlike the injection molding process. Especially relevant is the fact that we are extremely proficient in a wide variety of thermoforming processes at ATI. Consequently, we consistently bring home awards for our custom plastic parts!
Importantly, we welcome the opportunity to answer any questions you might have about whether the thermoforming process is right for you.
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Medical / Military & Aerospace / Recreation & Fitness / Retail & Consumer / Transportation
Pressure Formed Surgical Imaging Technology We begin, using the pressure forming process to custom thermoform the parts for GE Healthcare’s OEC Elite Miniview C-arm. Most noteworthy, with the pressure forming process, we are able to yield sharp radii where the various parts fit together. Next, the completed part calls for multi-part assembly. We have a variety […]
Vacuum Formed Beverage Dispensing System for Coke We have constructed this sleek, award winning product using the vacuum forming process. This is a multi-part beverage dispensing system, which we produce for Coke. Coke employs led touch technology for the dispensing choices. To construct this system, we have assembled three vacuum-formed parts made from metallic silver decorative sheet. […]
Vacuum Molding Process Used For American Airlines This part for American Airlines’ baggage handling trolleys was manufactured by ATI using the Vacuum Molding process. Additionally, we employed Design For Manufacturing to avoid potential problems later in the process. A challenging part due to size and material used, this project exemplified good use of DFM. Beginning early in the process, we spent […]
Vacuum Forming Process Used to Manufacture Seat Pan Insert We thermoformed this seat pan insert for the Aerospace Industry using the Vacuum Forming Process. To form this part we used an engineered resin, Lexan F6000. Thus, we had much the same processing requirements as for the Radel® material used in the Shroud Headrest part. Next, we form this part using a […]
Pressure Forming Process Used for Shroud Headrest This part is made from a Radel® resin which is a polyphenylsulfone material. Radel’s properties include very high impact and chemical resistance in addition to the toxicity properties stated above. Because of the physical properties of the sheet, the processing temperatures are very high, requiring the sheet to […]
Vacuum Formed Parts Used In Transportation Industry We assemble this Lavatory Door using two vacuum formed parts, attached together with adhesive. In addition, during that assembly process, an aluminum strike plate is inserted into the structure for mounting the hinge. Finally, we fill the entire assembly with a 2-part urethane foam for strength and sound deadening. We face an […]
Power Drape Forming is a Basic Thermoforming Process The Elevator is comprised of several drape-formed clear panels that make up various doors and wall sections. The material we used is clear Acrylic, drape-formed to a radius. We have a challenge in making the parts from this clear material. An example of this is dealing with airborne […]
Twin Sheet Thermoforming Helps Reduce Sports Impact Issues Twin sheet thermoforming was the perfect process for this cushioning pad system. And subsequently, we have gained unique experience in working with the very demanding family of Thermoplastic Urethanes. In part, this experience as come from making parts like this cushioning pad system for a new generation of football helmet. […]
Pressure Forming Process Used for Hospital Bed System We chose the pressure forming process to manufacture the MediGLIDER™ patient transfer system. This innovative patient transfer system was developed by ConMediSys. This lateral transfer system eliminates the need for heavy lifting in patient transfer. As patient transfers are a leading cause of workplace injury in hospitals and other […]
PROPRIETARY PRODUCT-Plastic Highway Gawk Screen Freeway Screens is a temporary, vacuum formed plastic highway gawk screen product. We developed and manufacture this gawk screen as our own proprietary product. During design stages we worked in conjunction with CALTRANS (California Department of Transportation), in addition to other states’ DOT’s, to comply with state safety requirements. Additionally, we […]
Pressure Forming Process Achieves Sharp, Crisp Detail We use the Pressure Forming Process to manufacture this part due to the sharp, crisp detail required. Additionally, we form the part on a male mold. The material is a custom colored, capped HIPS. In addition it is a very high gloss material. Created for: Waterpik
Pressure Forming Process Forms Medical Enclosures These parts for the medical industry are formed using the Pressure Forming Process. We thermoform this set of enclosures for an Ultrasound navigation device. 94V0 Kydex is the material we use. These parts display a molded undercut perimeter. Thus, we are able to create a very uniform joint between […]
Water Analyzer for Semiconductor Business Made With Pressure Forming Process ATI is pressure forming these covers for Sievers Instruments. This is a total Organic Count Water Analyzer widely used in the Semiconductor business. G.E. Analytical recently bought this water instrumentation and desalination equipment company. Contact Us Today For Assistance With Design and Manufacturing of Your […]
Monitor Enclosure Employs Pressure Forming Process We achieve crisp features and clean, uniform joints between parts by using the pressure forming process for this monitor enclosure. This monitor enclosure is the result of a 3 part assembly. Due to customer specifications, we used a custom-colored, fire-retardant Acrylic/PVC material. In addition we formed these parts in textured […]
Pressure Forming Process Combines With Twin Sheet For a Winning Combination The InVision 3-D printer consists of 11 high definition parts. In addition to combining the pressure forming process with the twin sheet process, we’ve also used the vacuum forming and compression mold processes. This printer brings 3-dimensional printing to the masses with innovative features, high […]
Pressure Formed Disposable Tray For Medical Industry This female, pressure-formed part with large undercuts on both sides is manufactured for one of our medical customers. Additionally, this part has a very deep draw. The material is a tri-layerd HIPS extrusion, with a custom colored cap on both sides. Also, we use a “field-of-color” regrind […]
Pressure Forming to Manufacture Imaging Enclosure Pressure forming is the process we use to manufacture this multi-part medical imaging enclosure. We exhibit exacting tool construction in these female pressure-formed parts, thus creating uniform mating gaps. In addition, we have created molded-in openings. We have used an FR ABS material for this part. Finally, we paint the parts to complete […]
Three female pressure-formed parts with perimeter undercuts that provide for consistent mating of components along parting lines. Material is FR ABS. Parts are painted.
Female pressure-formed part displaying not only sharp, crisp radii around recess, but also an undercut formed without the “witness lines” normally caused by core-pulls. Material is custom colored FR ABS. Texture is molded.
Pressure Forming Process Used to Create Smoke Evacuator This pressure formed enclosure is used to house a smoke evacuation system for an electro-surgical procedure. The material is a fire-retardant ABS/PVC blend and is painted. The part demands a very severe draw-ratio to get plastic all the way into the bottom. It is a female mold, […]
Twin Sheet Process Gives Added Support To Flooring Part This is a large Twin-Sheet part that is the floor of a wheelchair-compatible temporary shower. The twin-sheet process creates a part that is very strong, capable of withstanding the point-loading of a person in a wheel chair. Notice the detail on both the top and bottom surfaces. […]
Twin Sheet Flooring System for Animal Laboratories We designed and manufactured this large, 60″ x 121″ twin-sheet floor for use in modular animal laboratory environments. Additionally, we designed this part to be cut into smaller sections as the need requires. We used the twin sheet thermoform process, to give the additional strength needed to handle the […]
Surgical Helmet Wins Twin Sheet Award We formed this award winning shell of a Surgical Helmet using Twin Sheet Thermoforming. Importantly, this helmet offers protection from fluids during operations. Additionally, we designed it to house a ventilating fan. It also includes a plenum running over the top of the head to distribute cooling to the face. As previously […]
Therapeutic Bed Benefits From Twin Sheet Thermoforming We used our Technical Twin Sheet Thermoforming process to manufacture these parts for a therapeutic bed. This is part of a hospital bed Safety Siderail system. The system helps prevent patients from becoming wedged between the mattress and steel rails, a common issue with hospital beds. We twin-sheet thermoform the […]
Twin Sheet Forming Part Provides Impact Absorption We used the Twin Sheet Process to manufacture this part used in the medical industry. This part is a bumper used to surround the base of a mobile medical diagnostics computer workstation. Its purpose is to absorb the impact of running into door jambs. It is a twin-sheet […]
Small, Complex Part Ideally Suited For Twin Sheet Forming This Twin Sheet part we manufacture provides cooling to internal components in a medical diagnostics machine. This part is small with a complex geometry, thus making it ideally suited for the Twin Sheet process. In fact, there is really no other practical way to manufacture it. We manufacture this […]
Headboard Utilizes Twin Sheet Forming This Headboard is used on a bariatric bed system and constructed using Twin Sheet Forming. It’s function, in addition to being a headboard, is to provide a handle to move the bed. What is unique about the part is that it is twin sheet molded with an aluminum weldment “insert-molded” […]
Pressure Forming Process Used to Construct Mannequins ATI formed these clear, two piece plastic mannequins using the pressure forming process for Victoria’s Secret. We used a bronze tinted plastic to give the illusion of glass. In addition to the aesthetic challenge associated with a clear part, these parts involved complex trim geometry. Created for: Victoria’s […]
Twin Sheet Process Great Solution For Cushioning Product For this flexible cushioning product, we have utilized our award winning Technical Twin-Sheet process. In addition, we have employed different colors of TPU resins. Equally noteworthy, we have welded around the perimeter of the parts, as well as at the contact point of each ellipsoid. Cushioning Panel Mold […]
Pressure Forming Offers Just Enough Detail for This Exercise Enclosure We assemble this pressure formed enclosure from 4 female, pressure-formed parts. Initially, we mold undercuts around the perimeter, thus ensuring uniform mating of various parts. In addition, we have molded in an aggressive texture, using a HIPS material.
Vacuum Forming Severe Deep Draw We vacuum form this award winning, very challenging part for QubicaAMF. First of all, the Durabin has a very severe deep draw, and we make it from High Density Polyethylene, with a .312″ starting gauge. The challenge we face is a result of the draw of material. We are tasked with maintaining […]
Award Winning Twin-Sheet Formed Pin Setting System ATI made these two parts utilizing our Technical Twin-sheet process, which molds geometric features on both sides. This part is constructed from two panels, both Front and Rear. The assembly, shown in top view from the pin-setter side (facing the bowler) is comprised of two Technical Twin-sheet parts. We mechanically […]
Set of parts made on male molds with high gloss weather-able capped ABS. Part finish is smooth, without distortions due to high quality of tooling.
Pressure Forming Process Used for SUV Truck Wall We pressure formed this part on a female mold for an OEM automotive application. This part manifests unique automotive molded texture. The material we chose is HDPE with 25% talc added for stiffness.
Twin Sheet Construction Provides Exceptional Strength We have used Twin-Sheet construction for this machine base, thus providing exceptional stiffness in addition to the low weight. This machine base was a support for ice in the food and beverage industry. The material we used is utility ABS. Also, we have incorporated numerous weld zones between the ribs for […]
Pressure Formed Merchandiser Uses Two Types of Molds We manufactured this product from a set of pressure-formed parts. For one part we used a female textured mold and then, for the second one we used a highly polished female mold. Notice crisp tight joint between the two parts. We manufactured this Merchandiser from custom-colored ABS. Additionally, the display […]
See What The Twin Sheet Process Can Do For You This small 2.5″ x 6″ x .75″ part demonstrates many of the features possible with the Twin Sheet process: Dissimilar materials of different colors and gauge, a white ABS top surface, and a clear PETG bottom surface; pressure-formed embossed text; molded bosses’ formed in threaded […]
Twin Sheet Insulated Lid For Use in Clean Energy We manufacture this large insulated lid using the twin-sheet forming process. Ice Energy uses this approximately 6′ x 6′ part, as an insulated lid for an ice making machine. This machine is then used to generate air-conditioning coolant during peak usage hours with ice made from electricity in off-peak […]
Control Bezel Manufactured with Pressure Form Process We manufactured this pressure-formed using a female mold. We were able to achieve very sharp radii, formed in texture, and male and female undercuts to create a “snap-in” functionality. Created for: Johnson Controls
TWIN-SHEET FORMING FOR MAXIMUM STRENGTH We used the Technical Twin-sheet forming process to make this award winning processing tray for Optima Battery. We designed it to hold up to 200 lbs. across a 40″ span. In addition, it can withstand up to 200° F for 20 hours and not deflect more than .100″. ATI met this […]
Pressure Forming and Technical Twin Sheet Processes Used to Create TouchPoint We used both the Pressure Forming Process and our Technical Twin Sheet process for Lancer’s new TouchPoint beverage dispenser. In addition, Associated Thermoforming, Inc. is working with Superior Imaging to utilize a process of distortion screen-printing to complete this revolutionary new beverage dispenser project for Lancer. […]
Vacuum Forming Great Fit in the Clean Energy Industry In response to increasing demand for commercial rooftop solar applications, we used the vacuum forming process to help develop this solar panel. We were approached by Johns Manville (JM) in 2010 to collaborate in developing a thermoformed roof solar panel mounting system. JM asked us to help provide […]
Vacuum Formed Weed Eater Shield Due to the gentle radii in this design, we manufacture this agricultural part using the Vacuum Forming process on a male mold. ATI makes this part for Crary Industries, a manufacturer of agricultural implements. Additionally, we use a high molecular weight polyethelene material for this part.
Vacuum Forming Parts for Agriculture Industry Using the vacuum forming process, we manufacture this part for Crary. The Potato Picker Hopper is a part for one of Crary’s Lockwood Harvesters, and is used for harvesting potatoes. This is just one of the parts we manufacture for the agriculture industry. Additionally, and also for Crary, we […]