Custom Vacuum Forming & Thermoforming Services

Sendot Technology offers custom vacuum forming (thermoforming) for plastic enclosures, housings, trays, and covers — from a single prototype to low-volume production. We tool fast, low-cost molds and form PETG, HIPS, ABS, PC, and HDPE sheet to your CAD, then trim, finish, and ship worldwide.

Key takeaways

Vacuum forming heats a thermoplastic sheet until pliable, then uses vacuum to pull it tightly over a mold — ideal for large, thin-walled plastic parts.
Low tooling cost vs. injection molding (often 10–20× cheaper molds), so it wins for prototypes and runs of 1–1,000+ parts.
Common materials: PETG, HIPS, ABS, PC, HDPE, PMMA, PP; sheet thickness typically 0.5–6 mm.
Prototype molds in as fast as 3–7 business days; CNC-machined aluminum tooling for higher volumes and finer detail.
Upload your CAD file for a free DFM review and quote.

What is vacuum forming?

Vacuum forming is a type of thermoforming in which a sheet of thermoplastic is heated to its softening point, stretched over a single-surface mold, and drawn down by a vacuum that removes the air between the sheet and the mold. As the plastic cools it holds the mold's shape; the part is then trimmed to its final outline. Because it uses one-sided tooling and low pressure, vacuum forming produces large, lightweight, thin-walled parts at a fraction of the tooling cost of injection molding.

For deeper, more detailed parts — or sharper features and texture — we also offer pressure forming, which adds positive air pressure on the back of the sheet to push it harder into the mold. See our full guide: Vacuum Forming: What It Is and How It Works.

Vacuum forming materials

Material choice drives clarity, impact strength, temperature resistance, and cost. The most common thermoforming plastics we run:

Material	Key properties	Typical uses
PETG	Clear, tough, easy to form, food-safe	Clear covers, retail trays, guards, medical
HIPS	Low cost, rigid, easy to form & paint	Housings, internal trays, mockups, packaging
ABS	Impact-resistant, durable, paintable	Equipment enclosures, automotive interior
PC (Polycarbonate)	High impact & heat resistance, clear	Machine guards, light covers, visors
HDPE / PP	Chemical-resistant, flexible, durable	Trays, liners, outdoor & chemical parts
PMMA (Acrylic)	Optically clear, rigid, UV-stable	Displays, lenses, signage

Not sure which to use? Read our thermoset vs. thermoplastic guide, or send your part and we'll recommend a material in the DFM review.

Vacuum forming vs. injection molding

The fastest way to choose: vacuum forming wins on tooling cost and lead time for large, thin-walled parts at low volume; injection molding wins on per-part cost, detail, and tight tolerances at high volume.

Factor	Vacuum forming	Injection molding
Tooling cost	Low (one-sided mold)	High (hardened steel mold)
Best volume	1–1,000+	1,000s–millions
Part geometry	Large, thin-walled, single surface	Complex, detailed, two-sided
Lead time	Days	Weeks

Mid-volume and need molded-quality parts without steel tooling? Consider urethane vacuum casting or rapid tooling.

Applications & industries

Automotive — interior trim, panels, ducting, prototype body covers (automotive prototyping)
Medical — device housings, trays, sterilization packaging (medical device prototyping)
Industrial & equipment — machine enclosures, guards, covers, panels
Consumer & retail — point-of-sale displays, packaging, trays, casings

See products made by vacuum forming and full process steps in our vacuum forming guide.

Why choose Sendot for vacuum forming

Sendot by the numbers

20+ years in custom manufacturing (founded 2003, Guangzhou, China)
No minimum order — one prototype or a full low-volume run
10+ thermoforming materials in 0.5–6 mm sheet
In-house CNC mold making, trimming (CNC/laser), and surface finishing
Worldwide shipping with English-speaking engineering support

Because we run CNC machining, 3D printing, and finishing under one roof, we can build your forming mold, form the parts, trim, and finish them in a single coordinated project.

Frequently asked questions

What is the difference between vacuum forming and thermoforming?

Thermoforming is the umbrella term for any process that heats a plastic sheet and forms it over a mold. Vacuum forming is the most common type of thermoforming, using vacuum suction to pull the sheet onto a single-sided mold. Pressure forming is another type that adds compressed air for finer detail.

How much does a vacuum forming mold cost?

Vacuum forming tooling is far cheaper than injection molds — often 10–20× lower. Simple prototype molds (wood, resin, or 3D-printed) can be very low cost, while CNC-machined aluminum molds for production cost more but last for thousands of cycles. Upload your part for an exact quote.

What materials can you vacuum form?

We commonly form PETG, HIPS, ABS, polycarbonate (PC), HDPE, PP, and acrylic (PMMA) in thicknesses from about 0.5 mm to 6 mm. Material is chosen for clarity, impact strength, temperature resistance, and budget.

When should I use vacuum forming instead of injection molding?

Choose vacuum forming for large, thin-walled parts in low to mid volumes (1–1,000+), when you need low tooling cost and fast lead times. Choose injection molding for small, detailed parts in high volumes where the lowest per-part cost matters.

What is the minimum order quantity for vacuum forming?

There is no minimum order. Sendot Technology will form a single prototype or a low-volume production run, then scale up as your project grows.

How fast can you deliver vacuum formed parts?

Simple prototype molds can be ready in 3–7 business days, with formed parts shortly after. Lead time depends on part size, material, tooling type, and finishing. Tell us your deadline and we'll confirm a schedule with your quote.

Get a vacuum forming quote

Upload your CAD files for a free DFM review and a real-time quote — from a single prototype to low-volume production, shipped worldwide.

Request a Quote