Ideal for Great-Looking, Highly Detailed Cosmetic Parts

The pressure forming process can yield durable, highly detailed cosmetic plastic parts that rival those made by injection molding. In fact, pressure forming provides a number of advantages:

pressure forming produces high-detailed thermoformed plastic parts
  • Lower tooling costs
  • Easier prototyping and faster turnaround on tooling
  • Highly cosmetic—and great-looking—parts are possible
  • Wide variety of available thermoplastic materials to meet most specifications
  • Possible to decorate parts for further cosmetic enhancement

Pressure Forming Works Best If You Need…

Recognize your needs in any of the following? Plastic Profiles could be your solution:

Highly engineered cosmetic parts

Pressure forming works exceptionally well for cosmetic parts that have molded in color and demand an extremely detailed surface.

Physically large parts

For parts larger than 24” x 24”, the economics of pressure forming become especially attractive compared to other plastic processes that could allow for the same part features.

Estimated volumes in hundreds to thousands

Establish market presence without committing to hundreds of thousands of dollars in injection mold tooling.
pressure forming for large, engineered cosmetic parts
the perfect method for manufacturing multiple mating parts.

Rapid development and speed to market

With pressure forming, a single part can be manufactured in as few as four to six weeks.

Color-matched parts with sharp, flawless detail

Thermoplastic material with molded-in color is available in a spectrum of colors (at no extra cost). And with the pressure forming process, parts have no gate marks, knit lines, sink marks, ejector marks, etc.

Multi-part programs with molded-in color

This is the ideal process for two or more mating parts, where each one increases the degree of difficulty exponentially. In addition, using molded-in color material saves on painting time and costs.

Design flexibility

Pressure forming works effectively for parts needing decorative materials or coatings. The technique also works great for parts with zero draft, complex undercuts, molded-in features, and trim features that need to be easily adjusted.

Durability and industry-compliance

Thermoform material is extremely versatile and can meet the industry demands and performance requirements for everything from medical devices and fitness equipment to electrical enclosures and industrial safety equipment.

Lightweight parts

Thermoform plastic material is considerably lighter than steel, aluminum, and fiberglass yet can still meet demanding specifications.

thermoformed heavy-gauge pressure formed parts with high detail.

Understanding the Pressure Forming Process

Pressure forming involves heating a single sheet of extruded thermoplastic to a softening point and applying pressure of up to 100 psi to force the material into a female tool. The next step is evacuating the air between the sheet and the mold.

The combination of pressure, the right material, and a well-designed, intricate mold can produce highly detailed parts matching those made from injection molding.

step by step pressure forming process
Moreover, pressure forming can yield parts that are equal to or better than injection molded parts—in detail, appearance, and performance.
Profile Plastics, Inc. Logo

The Pressure Forming Innovator for nearly 40 Years

Profile Plastics specializes in providing highly cosmetic, close tolerance, pressure-formed parts to a wide array of OEM manufacturers.

In 1983, we produced our first pressure-formed part. Since then we’ve led the industry by continually improving both the process and the parts themselves. We’ve also built an exceptional team of experienced engineers who help optimize part designs for improved performance and cost-efficiency.

Along the way, we’ve demonstrated the following to thousands of customers: Pressure forming—with the appropriate tooling, detailed design, precision equipment, and quality control—can be an inherently better option than injection molding.

Interested in working with us on a project?