Thermoforming
A cost-effective plastic forming process ideal for creating lightweight, reusable packaging with rapid turnaround times and competitive tooling costs.
Thermoformed packaging solutions
What is thermoforming?
Thermoforming, or vacuum forming, is a manufacturing process in which a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and then trimmed to create a usable product.
Thermoforming is commonly used for producing packaging, trays, covers, and various other plastic parts. It is valued for its efficiency at competitive tooling costs.
Nefab's customized thermoformed packaging portfolio
Nefab’s thermoformed plastic packaging includes pallets, trays, cushions, inserts, clamshells, dunnage and more. These can be made in a wide range of sizes and material thicknesses from thin gauge to heavy gauge. We specialize in custom packaging solutions that can be complemented with standard offerings.
Trays
Reflex cushioning
Pallets & lids
Inserts & inner fittings
Rack dunnage
Clamshells and blisters
Explore our standard plastic packaging solutions – Now available online!
For our US-based customers, our online shop offers quick and easy access to our standard plastic packaging solutions.
Enjoy seamless ordering, fast delivery, and sustainable options – all in one place. Our product range includes thermoformed pallets, plastic inline trays, and more – designed for durability, efficiency, and sustainability to support your operations.
Applications of thermoformed packaging
When should you choose thermoforming?
Nefab is an expert in thermoformed solutions for any inbound and outbound applications in various industries, such as automotive, e-mobility, and Li batteries, as well as datacom, semicon, and electronics.
Thermoforming is an excellent choice for companies that need packaging...
...in low to medium production volumes:
Thermoforming is a cost-effective option for producing small to medium quantities, with lower tooling costs and shorter lead times than injection molding.
...that is reusable:
Thermoformed packaging can be engineered to be extremely durable and is a great choice for a returnable application.
...that is modular:
Nefab’s library of abrasion resistant TPU inserts makes it easy to reuse thermoformed trays in new programs.
...with a short lead time:
Thermoforming allows businesses to achieve faster time-to-market with lower tooling costs and quicker setups.
...with representative prototypes:
Thermoforming supports the production of representative parts from prototype tooling, ensuring reliable assessment and testing.
...that is suitable for automation:
When using the right materials, thermoformed packaging supports automatic handling.
…that is made from recycled content:
Thermoformed packaging can be made from up to 100% recycled content, including post-consumer recycled material.
…that is recyclable:
Nefab's thermoformed packaging is made from recyclable materials creating a closed loop.
Nefab's thermoforming capabilities
1. Design and engineering
Based on customer requirements, our experienced engineers develop custom concepts. They design specifically for the thermoforming manufacturing process with the whole packaging flow in mind.
2. Samples / Prototypes and Testing
Utilizing dedicated in-house 3D printers and thermoforming machines, Nefab can quickly and cost-effectively manufacture samples. In our certified ISTA labs, these samples undergo rigorous testing.
3. Tooling / Molds
Nefab has its own in-house tool or mold workshops across the world, as well as a network of partners, to create tooling efficiently.
4. Manufacturing
We manufacture custom packaging solutions in-house with a wide range of thermoforming machines from thin gauge to heavy gauge. In addition, we can leverage a network of partners.
Nefab’s thermoformed plastic packaging can be made from various types of plastics, such as HDPE, HWMPE, PS, HIPS, PET, ABS, ABS-TPU, HDPE-TPU, PP and more, based on the need for each application. Optional protective features include:
- ESD protection due to conductive material
- Anti-scratch surfaces and vibration protection from adding TPU inserts or a TPU layer
- Cushioning and dust protection through special design characteristics
- Chemical resistance due to the selected material (e.g. HDPE)
Quality control: At Nefab, we follow standardized quality routines to ensure we consistently deliver high quality parts according to customer specifications.
The thermoforming process
1. Heating
A plastic sheet is heated until it becomes pliable.
2. Molding
The heated sheet is then placed over a mold.
3. Vacuum / pressure application
A vacuum or pressure is created, pulling the sheet tightly against the mold's surface.
4. Cooling
The formed plastic is allowed to cool and harden into its final shape.
5. Trimming
The excess material is automatically or manually trimmed away to create a usable product.
5. Logistics services
As part of complete packaging and logistics solutions, Nefab offers added logistics services. This includes assembly work such as adding labels, label holders, loose inserts, tracking devices etc. Pooling services cover all operations required to provide returnable packaging when and where it is needed, e.g. repairing and cleaning.
6. Recycling programs
Thermoformed plastic packaging is recyclable. Nefab offers take-back programs for used or discarded plastic packing, where possible. Once the packaging has fulfilled its lifecycle, we collect it for recycling and reuse it as raw material to produce new plastic packaging.
Benefits of Nefab packaging solutions
Nefab saves environmental and financial resources by optimizing supply chains. We do so by innovating together with our customers to create smarter packaging and logistics solutions while always respecting people and ethical standards.
Complete solutions
We provide complete packaging and logistics solutions that reduce total cost and environmental impact throughout the supply chain.
Engineering expertise
With over 250 engineers in 30 locations globally, we collaborate closely with customers to design, prototype, test, and deliver tailored packaging solutions.
Sustainability focus
Nefab's solutions reduce carbon footprints by 31%, on average, reflecting our commitment to sustainability within our operations and offerings.
Global footprint
With 75 years of experience and a presence in over 38 countries, we deliver global solutions with local support.
Get in touch
Contact your local packaging expert
Looking for thermoformed packaging solutions? Reach out to us today! Our team of experts in more than 38 countries is ready to collaborate, innovate, and deliver solutions tailored to your unique challenges. Contact your local sales representative for more information.
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