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Thermoforming processes involve heating a plastic sheet until it is pliable and then forming it over or into a mold. The sheet is then cooled and the formed part is ejected from the mold. This method is widely used for producing a variety of plastic products, from packaging and containers to automotive components and recreational equipment.

There are several variations of thermoforming. Vacuum forming is the most common, where a vacuum is used to draw the heated plastic sheet onto the mold. Pressure forming utilizes compressed air to force the plastic onto the mold, allowing for finer details and sharper corners. Drape forming involves simply draping the heated sheet over a mold and allowing gravity to assist in the forming process, often used for simpler shapes.

The key advantage of thermoforming is its cost-effectiveness for producing large quantities of parts, especially when complex internal structures are not required. It allows for relatively low tooling costs compared to injection molding. The process is also adaptable to a wide range of thermoplastic materials, including polystyrene, polyethylene, polypropylene, and PET. The thickness of the plastic sheet can vary significantly, influencing the final product's strength and rigidity. Cycle times are generally fast, contributing to efficient production.