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Thermoforming

TPI offers state-of-the-art technology for thermoforming fabric material, which transforms flat material such as polyester or nylon into a finished 3-dimensional shape. The thermoforming fabric process begins with the selected fabric laminated to one or both sides of foam and is then placed in a 2-piece mold. Heat and pressure are then applied, which permanently molds the laminate into a semi-rigid product.

The benefits of thermoforming fabric material include:

  • Protection – Thermoformed products are semi-rigid. They can help protect your products from impact, dust, sun, moisture, and other environmental factors.
  • Attractive style – Thermoformed products have a smooth, contoured, wrinkle-free look. Stylish hardware and artwork can be added for styling and additional visual appeal.
  • Custom fit – Thermoformed products can be molded into exact shapes desired for your components. Die cut foam or molded plastic inserts can be added for extra protection of instruments. Dedicated instrument cavities can also be formed directly into the product.
  • Lightweight – Thermoformed products are easy to transport.
  • Lower tooling cost – Thermoformed product tooling is less expensive than blow molded or injection molded tooling for most applications.

We sew the parts to the desired finish once the shapes are completed. This additional process is a cosmetic alternative when providing protection using foam. It is another effective method in the textile and foam industry for finishing products.

In thermoforming fabric solutions, we can add an even higher degree of functionality by varying fabric and foam types and even creating combinations that can be incorporated into your product. This helps us provide a lighter weight, softer, and protected product. Additionally, you can make your product stand out from the competition by incorporating a custom pattern or prototype.

We work regularly with medical, airline, food and other related industries who need to protect their equipment. Call us today and we will help you with your thermoforming fabric requirements and equipment specifications!

Contact Us

Looking for thermoforming services?

We work with medical device and OEM manufacturers as your single source for custom cutting, sewing and sealing.  Contact us to get started on your project today!