Ideal for prototype development and low-volume production

Vacuum Forming

Ideal for prototype development and low-volume production, Vacuum Forming offers several advantages over other forming processes. Extremely adaptive to design needs and able to produce large volumes of parts without costly machinery and tooling.

A Viable Choice
Vacuum Forming (also known as thermoforming) is the technique in which plastic is heated to a manipulative state and form-fitted against a concave surface by way of suction. The material and process is optimized for cost-effectiveness and it is relatively easy to later make engineering changes to a part. Molds can be made from multiple materials ranging from wood to metal. Vacuum-formed components can be used in place of complex fabricated sheet metal, fiberglass or plastic injection molding.

Meeting Every Need
At Aerosport, we offer Vacuum Forming for a variety of projects:
• Small to large designs
• Quick-blister and clam-shell packaging prototypes
• Production-quality prototypes

We offer three variations:
• Cast Aluminum Molds – fast aluminum molds, can also be used in pressure forming applications
• Machined Aluminum Molds – cut out of solid aluminum block, for packaging and trays
• Composite Molds – lower cost alternative, produces high quality parts that last a very long time

Ideally suited for:
• Automotive
• Consumer products
• Packaging
• Retail and display
• Sports and Leisure
• Electronics
• Industrial applications

Typical Materials Used
ABS – Acrylonitrile Butadiene Styrene
PETG – Polyester Copolymer
PA – Polystyrene
PC – Polycarbonate
PP – Polypropylene
PE – Polyethylene (sheet & foamed sheet)
PVC – Polyvinyl Chloride
AC – Acrylic


Our latest projects

After being in the additive manufacturing business for the better part of three decades, we’ve seen and utilized many 3D printers. Some we really liked, and others are not worth the hype. One model we’ve stood by and operate every day is the HP Multi-Jet Fusion 3D Printer. Whether we are producing prototypes or are […]


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Corporate Office

Our clients consider us an extension of their design and development team by helping them produce the highest quality prototypes, appearance models, working models and machined parts.

Office Hours: Mon – Fri, 8:00am – 5:00pm

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Canal Winchester, Ohio

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