Thermoformed Plastic Parts in Use – Detailed Applications

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.

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 KLT 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

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.