Thermoforming involves the controlled heating of a thermoplastic material to a temperature where its shape may be altered to the shape of the mold. The physical change to the preheated thermoplastic is accomplished by vacuum, air, pressure or direct mechanical force.

The advantages of thermoforming are the capability to form large parts without expensive equipment and tooling, ease of producing large quantities, inexpensive mold and design modifications, and laminated or foam-filled parts capability. Thermoplastics most commonly specified are acrylic, ABS, PVC, CAB and polycarbonates. Exotic types include Turlan, Espel and Teflon. Precolored sheets are also used in addition to the secondary steps of robotic painting, pad printing, hot stamping and silk screening. KEYWORDS for this process: Vacuum Forming