At Key Packaging, we know that your needs are unique and we customize our process around the specifics of your project to ensure quality, timely delivery, and customer satisfaction.

Our Process

When you work with Key Packaging, we become your thermoforming partners.

Whether you have a physical sample or a CAD drawing of your part or product, our designers will partner with you to create a drawing and produce a prototype piece that matches your standards. Our experienced design team uses SolidWorks technology to ensure tight tolerances and industry expectations are met for your custom thermoformed part. Once the design is approved, the production tooling is constructed. We require your final approval before we move forward to the production run phase.

We offer a comprehensive thermoforming process service. Not only do we design your part or product and produce it, we also manufacture your custom prototype mold as well. We manufacture molds in REN (synthetic polyurethane) or aluminum materials to ensure durable, long-lasting molds. Your custom mold design can be manufactured to include:

  • Trim Die
  • Plug Assist
  • Grid Assist
  • Pressure Box
  • Anvil
  • Stacker and more!

After we manufacture your custom mold, we rigorously inspect and test it to ensure it meets your requirements and industry standards.

All design and prototype work is carried out on-site, at our facility by our talented team of design engineers and machinists. Each project is customized. We offer both small and large product runs, with a minimum of 1,000-pound buy for special order materials. Once your project is complete, we electronically store all files and designs digitally in our secure system to streamline any future orders.

Thermoforming Materials We Use

We have the skill and experience to work with a wide range of materials depending on your part needs and final applications. During the design process, our team will help you choose the best material to help you lower manufacturing costs and provide guidance on the best materials to meet industry sustainability specifications.

The most common thermoforming materials we use are:

  • HIPS (High Impact Polystyrene)
  • PVC (Polyvinyl Chloride)
  • PET (Polyethylene Terephthalate)
  • PETG
  • RPET
  • PP (Polypropylene)
  • Polyurethane
  • HDPE (High Density Polyethylene)
  • ABS (Acrylonitrile Butadiene Styrene)

Our Machining Capabilities

We provide high quality, custom thin gauge thermoforming plastic solutions. At the heart of our manufacturing operation, we have 18 state-of-the-art, in-line thermoforming machines featuring customized computer control panels that provide precise management for temperature, pressure, and cycle time. No project is too large or too small.

The variety of thermoforming machine sizes, robotics, and match metal die-cutting allow Key Packaging to serve both large and small customers in the following industries:

  • Medical Device Packaging
  • Automotive Trays
  • Pharmaceutical Packaging
  • Cosmetic Packaging
  • Retail Packaging
  • Electronic Packaging
  • Food Packaging

Want to get started on your custom thermoforming project? Contact us today!