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Midland Plastics Custom plastic components manufacturer, fabricator and assembler

Custom Pressure Forming

Custom pressure forming is similar to vacuum forming except that it uses greater pressure in molding the finished part. Like vacuum forming, it turns a flat, thermoplastic sheet into a three-dimensional part by heating the sheet until it is formable. The sheet is then forced into a mold under high pressure. Typical pressure for this type of forming is 40 to 50 pounds per square inch – and in some cases pressures may exceed 100 psi. By contrast, vacuum forming is done at 14 psi.

Custom Pressure Formed Parts


Midland’s custom pressure forming offers our customers many benefits:

  • It produces sharper edges and corners that give parts an injection-molded look for a much lower tooling cost.
  • It incorporates texturing directly into the mold rather than on the sheet. This allows for multiple surface textures on one part.
  • It allows molded logos and lettering to be incorporated onto the surface of the part.

Although the cost of pressure forming tooling runs between 30 and 50% more than vacuum forming tools, it is still significantly less than typical injection-molded tooling. With the addition of movable tooling to create undercuts and bosses, customers can have an injection molded look at a fraction of the cost.

Midland has years of experience with such custom pressure forming applications as:

  • Bezels
  • Control pads
  • Medical instrument covers
  • Monitors and housings

As with vacuum forming, we use pressure forming most frequently for these plastics:

  • ABS
  • Styrene
  • Kydex (acrylic/PVC alloy)
  • Acrylic
  • PETG
  • Polyethylene
  • Polypropylene
  • PVC
  • Polycarbonate
  • Butyrate


Custom Pressure Forming from Midland Plastics