Thermoformed Parts in Practice
Thermoformed Plastic Parts in Use – Detailed Applications
Thermoformed plastic parts play a crucial role in almost every industry, from manufacturing and mechanical engineering to medicine and food production. In this article, we take a closer look at the various applications of thermoformed plastic parts across different industries.
Amin Lakhal
Updated on August 26, 2026
Contents
Applications of thermoformed parts – Key points at a glance
- Thermoformed parts are produced by deep-drawing plastic sheets and enable the cost-effective manufacture of customised moulds for many industries.
- Material properties such as ESD protection, food safety or UV resistance make thermoformed components suitable for a wide range of applications, e.g. in the medical, electronics or packaging sectors.
- The applications range from transport trays and enclosures to protective covers, inserts and trays in the industrial, logistics and consumer goods sectors.
- As an experienced digital manufacturer of thermoformed parts, formary supports you every step of the way, from design through to series production.
→ Enquire about thermoformed parts now
What Are Thermoformed Plastic Parts?
Thermoformed parts, also known as deep-drawn plastic parts, are three-dimensional products produced by plastic deep drawing (plastic thermoforming). In plastic deep drawing, a semi-finished product is heated and drawn into a deep-drawing die using vacuum or pressure. This results in bespoke products for packaging, logistics, mechanical engineering or medical technology.
Typical characteristics of deep-drawn components:
- Large component dimensions are possible
- low tool costs
- short project durations
- cost-effective for small to medium-sized production runs
Technical thermoformed parts are primarily used when components need to meet functional requirements such as ESD protection, UV resistance or high dimensional stability.
Properties of Thermoformed Plastic Parts
Thermoformed plastic components are highly versatile, as they can be adapted to specific industries through different material configurations. Depending on the material, thermoformed components offer specific properties that are crucial in sectors such as medical and electronics :
- ESD protection for sensitive electronic components
- Cleanroom hygiene and sterility for medical technology and the pharmaceutical industry
- Food safety for food packaging
- High-quality appearance for retail and display packaging
Popular materials for thermoformed plastic parts
There are numerous options when it comes to choosing the material. The following are particularly commonly used:
- PVC: Durable and versatile
- PET-A: Transparent and cost-effective
- ABS: Strong mechanical and thermal properties
- PS: A standard reference plastic for thermoforming
- PP (Polypropylene): Chemical resistance and lightweight
Plastic thermoformed parts therefore meet both functional and aesthetic requirements. If you’d like to know how plastic differs from metal, read our article Plastic vs. Metal: A Comparison.
Can Thermoforming also be Used to Produce High-Quality Visible Plastic Parts?
Thermoforming is suitable not only for simple trays and packaging, but also for high-quality visible parts such as plastic housings, machine covers, equipment enclosures, or design components. Depending on the application, thermoformed visible parts can be produced with smooth, matte, high-gloss, grained, or textured surfaces, custom colors, paint finishes, and printing.
Typical high-quality visible parts produced using thermoforming include:
- Housings for medical and electronic devices
- Machine and equipment covers
- Robot housings
- Vehicle and caravan interior and exterior panels
- Control panels and decorative panels
- Transparent covers
- Design and presentation parts
Learn more in our article on surface finishing for medical housings.
Can a thermoformed part look like an injection-molded part?
With the right choice of material, tooling, and process design, thermoformed plastic parts can achieve a very high-quality visible surface. Compared with injection molding, the main limitations are very small details, integrated complex functional features, and very tight tolerances.
The advantage of thermoforming, however, is particularly evident for large-surface-area components and small to medium production runs, as tooling costs are typically lower.
Applications for Thermoformed Plastic Parts
Thermoformed parts are used in a wide range of industries. We have divided the main applications into five categories.
Transport and storage
Thermoformed parts for transport and storage are used across all sectors of industry. Typical applications include:
- workpiece carrier
- load carrier
- ESD-Trays
- Stackable trays
- Tray packaging for metal parts
- Trays with colour strips
- Inserts for SLC containers
Automation and Production
Automation trays are used in production lines. They feature precisely fitted mould cavities and optimised stacking methods, enabling robots to automatically grip and handle the components. A tray can pass through various production stages, which makes processes more efficient.
When using thermoformed parts for automation and production, you therefore benefit from:
- high-precision positioning
- Stackability
- Process integration
- low damage rate
Thermoformed deep-drawn trays are therefore particularly suitable for production lines handling a variety of product variants. Read more in our article → Automating production with plastic trays.
Inlays & Inserts
Plastic inserts and liners are used in storage systems such as cases, drawers and packaging. Their purpose is to securely store components.
In addition to the safety of small components, deep-drawn inserts are also used as
- Inlays for packaging
- Plastic drawer inserts
- Suitcase liners
- Thermoformed packaging
- Presentation packaging
- Medical blister packs
- Cosmetics packaging
are used. Plastic inlays are generally scratch-resistant and resistant to cleaning agents. Thermoformed inlays can be visually adapted to your corporate identity guidelines to present a high-quality product with the desired distinguishing features.
Covers & Housings
Thermoformed parts in the form of plastic covers protect sensitive equipment, machinery or other key components. They keep out dust, moisture and mechanical stress whilst ensuring a clean appearance.
Typical applications for covers and enclosures
- Medical technology enclosures
- Protective covers for CNC parts
- Machine covers
- Caravan cladding
- Tractor body panels
- Battery compartment
- Plastic electronics enclosures
Examples of Cover & Housing Applications
| Outdoor Applications | Indoor Applications |
|---|---|
| Exterior casings | Covers for electronic devices |
| Wheel arches & construction machinery covers | Motor covers |
| Cable ducts & covers | Distribution housings |
| Enclosures for switch cabinets | Protective housings for instruments |
| Climate control system enclosures | Security & alarm system casings |
Containers & Trays
Thermoformed containers made of plastic are used in many industries as
- Planters
- Paint trays
- Moulds for casting
- ESD container
- Thermoformed trays
The key factors here are dimensional stability, recessed grips and a precise fit, which enable the safe handling of the components to be transported and stored.
Material requirements for thermoformed parts in the form of deep-drawn containers
ABS and ASA are the materials most commonly used for thermoformed containers intended for outdoor use, as these materials are UV-resistant.
Conclusion – Thermoformed Plastic Parts Offer Endless Possibilities
Thermoformed parts offer a flexible and cost-effective solution for a wide range of industrial applications. Whether transport trays, machine casings, housings or containers, thermoformed plastic parts provide functional, lightweight and cost-effective components.
As an experienced digital manufacturer of thermoformed parts, formary supports you every step of the way, from design through to series production.
Frequently Asked Questions About Plastic Thermoformed Parts
What are thermoformed parts?
Plastic thermoformed parts are produced by thermoforming plastic sheets or rolls. In this process, the semi-finished products are heated and drawn into a mold, creating custom shapes for packaging, enclosures, or transport solutions.
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