Video: The ultimate guide to optimizing part design

Video: How to get the most out of thermoforming your part

Key design concepts were the highlight of our December 2025 webinar “Optimizing part design for successful thermoforming.” The program was hosted by the SPE’s PD3 division.

Watch the recording to discover:

4 Geometry & forming factors
2 Surface & structure factors
2 Post-process factors

Along with:

Process overview of heavy-gauge thermoforming
Materials impact
Tooling impact

Grasp these concepts to adapt your product design for thermoforming and ensure a successful product launch.

Your go-to expert source is here to help! The form at right lets you access the webinar recording and the PDF of the slides.

Design Guidelines. Geometry & Forming Factors, Surface & Structural Features, Post-Forming & Assembly Factors

PD3 Design Guidelines

Draft. Compensates for thermal shrinkage, 100-300°F cooling range. Helps release part from mold. Improves material distribution.

PD3 Draft

Key to understanding thermoforming. Fundamentally a stretching process, Finite amount of plastic to stretch. Heated material thins as it stretches.

PD3 Draw Ratio

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