Project Planning in Thermoforming – From Concept to Mass Production

Project Planning in Thermoforming – Key Points at a Glance

• formary supports thermoforming projects from the initial enquiry right through to series production – quickly, precisely and cost-effectively.
• Four prototyping options (3D printing, urethane, partial-segment moulds and production moulds) ensure prototypes and tests are a perfect fit.
• You will receive your quote within 24 hours; production is carried out by certified DACH partner companies.

→ Enquire about a thermoforming project now

How does a Thermoforming Project Progress from Development to Series Production?

With formary, you have a reliable partner at your side who optimizes the entire process and finds the best possible solution for your specific requirements. We'll show you how the process of a thermoforming project is structured at formary and which steps are necessary to successfully realize your custom plastic parts.

Co-founder Lisa-Marie Bittner explains the exact project workflow in this video:

ℹ️ New to thermoforming? Our Supplier Guide for Plastic Thermoformed Parts explains what to look for when selecting a supplier and which questions you should clarify in advance.

Quick Overview of a Thermoforming Project

Quote, Prototype, Start of Production: An Overview of the Key Timeframes

In the following sections, you'll learn exactly how a thermoforming project progresses from development to mass production.

1. Inquiry and Data Release

The quality of the inquiry determines how quickly and how reliable a quotation comes back (see article 10 Details a plastic thermoformer needs from you). A complete inquiry package contains:

• 3D data in neutral format (STEP preferred), ideally with an additional 2D drawing with dimensions and tolerances.
• Quantity per call-off and per year. Tool selection depends on this.
• Material with specific type (e.g., ABS, PS, PET-G, PC, PMMA) or at least functional requirements (recyclate, impact resistance, UV resistance, food contact, ESD protection, flame retardancy).
• Surface and appearance (graining, high gloss, laminated, painted, printed).
• Markings such as texts and symbols, Poka-Yoke, color stripes
• Dimensions (length x width x height)
• Additional information relevant to the project (latest quotation date, specific application, etc.)

Enter your requirements in our configurator and submit your inquiry.

2. Feasibility Check

Here we check whether the part can be thermoformed and which design points need to be clarified in advance. Typical focal points of a Design for Manufacturing review are:

• Draft angles: walls that are too steep cannot be demolded.
• Undercuts: possible, but expensive, because slides or additional tools are required.
• Wall thickness distribution: during thermoforming, the material stretches, thin wall areas occur especially in deep corners.
• Radii: inner radii that are too small lead to stresses and cracks.
• Tolerances: Slight dimensional deviations can occur during the thermoforming process. Therefore, the maximum possible tolerances for production must be considered.

3. Quotation

We check your data for feasibility and implementation and calculate a quotation for your thermoformed part within 24 hours. This contains the following information:

• Tooling costs (one-time): depend on size, number of cavities, and tool material.
• Part price (per piece): depends on material, sheet thickness, cycle time, downstream processes, and quantity.
• Delivery time for initial samples and for series production.

At the same time, we also make suggestions for suitable sampling options and prototype production.

4. Data Approval

Upon order, we create the design of the thermoformed part based on your specific needs. We make sure that we have understood all your requirements in order to design the best cost-benefit optimized thermoformed part.

If necessary, we select the optimal combination of material, stability, and tool design. You approve the design, and we can start sampling your individual prototype.

5. Tooling and Sampling

Depending on your deadline, you will receive samples for the most suitable option. There are four sampling methods, each chosen based on the purpose of the sample.

3D-Printed Thermoforming Tools

Ideal for fast sampling of small part segments. However, due to high temperatures and stress, only a few samples (1-3 pieces) can be produced.

• Max. number of samples: 1-3 pieces
• Production time: 3-5 business days
• Cost: €€€€€
• Best for: Form-fit tests, short-term prototypes, and small series in standard materials.

Samples from Ureol Tooling

Ureol prototype tools allow for near-series thermoformed parts comparable to aluminum tooling. However, Ureol is less heat- and pressure-resistant, limiting production to 5-10 samples.

• Max. number of samples: 5-10 pieces
• Production time: 1-2 weeks
• Cost: €€€€€
• Best for: Near-series prototypes with higher durability than 3D-printed tools.

Samples from Partial-Series Tooling

A partial-segment aluminum tool enables realistic testing while reducing costs compared to full series production. It serves as an intermediate step toward the final series tool, requiring additional manufacturing time.

• Max. number of samples: Infinite
• Production time: 2-3 weeks
• Cost: €€€€€
• Best for: Samples from partial segment tools provide optimal series accuracy.

Samples from Full-Series Tooling

Aluminum series tools enable the production of approval samples under optimal conditions. For high quantities, multi-cavity tools are the most cost-effective option.

• Max. number of samples: Unlimited
• Production time: 2-6 weeks (up to 10 weeks depending on size and complexity)
• Cost: €€€€€
• Best for: Mainly intended for final product approval prior to the start of series production; less suitable for early test samples.

6. Sample Approval and Series Production

After successful sampling and any necessary adjustments, mass production begins. Depending on the material, tooling design, and production capacity, the lead time from approval to delivery is approximately 3-5 weeks. Production is carried out using high-quality aluminum series tools on automated production systems.

7. Shipping

After a thorough quality inspection, your series production is prepared for shipment. Our logistics team ensures that your delivery arrives on time and in perfect condition.

Project Planning in Thermoforming with formary - A Summary

Not all phases can be accelerated. Tooling takes physical time, initial sample inspection requires care. What can be shortened with formary as a B2B platform:

• Large supplier network: Your inquiry is directly matched with the right partner from the formary supplier network. This way, you can always access capacity from certified companies in the DACH region.
• Quotation phase: You receive a quotation within 24 hours if the inquiry is complete.
• DfM loops: Our automated DfM analysis reflects the critical points directly after upload.
• Tray concepts: With the 3D Tray Generator, you can create an initial tray concept in seconds instead of weeks.
• Single Point of Contact: You have one contact person throughout all phases, even if multiple manufacturers are working in the background.

Are you currently planning your thermoforming project? Then contact us - we support you from idea to implementation.