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Thermoforming is a versatile and efficient manufacturing process where a plastic sheet is heated to a pliable forming temperature, shaped to a specific mold using pressure, vacuum, or mechanical force, and then trimmed to create a usable product. The process begins with a continuous sheet of thermoplastic material, such as ABS, PVC, PETG, or polystyrene, which is heated in an oven until soft. It is then rapidly transferred over a mold, and a vacuum is applied, sucking the sheet into the mold's contours to replicate its precise shape. Once cooled, the formed part is ejected and the excess material is trimmed away. This method is distinct from injection molding, as it forms from a sheet rather than liquid resin, making it ideal for producing large, relatively shallow parts with a high surface-area-to-volume ratio.

The applications of thermoforming are ubiquitous, spanning numerous industries due to its cost-effectiveness for medium to high-volume production runs. Most consumers interact with thermoformed products daily; common examples include blister packs and clamshell packaging for electronics and consumer goods, disposable food containers, and refrigerator liners. Beyond packaging, the process is critical in creating substantial components like automotive interior panels, bathtubs, and aircraft cabin liners. A key advantage is the relatively low cost of the molds, which are often made from aluminum or composite materials, compared to the hardened steel molds required for injection molding. While thermoformed parts are generally single-walled and not as dimensionally precise as their injection-molded counterparts, the process remains the go-to solution for creating durable, lightweight, and complex shapes efficiently, making it a cornerstone of modern mass production.