Material selection happens early because it drives tooling decisions, forming behavior, and field performance. Committing to a material before understanding the tradeoffs is a common and costly mistake.
Common thermoforming materials
- ABS: a tough, general purpose plastic widely used for enclosures and housings.
- KYDEX: known for durability and fire performance, common in aerospace interiors.
- HDPE: lightweight and chemical resistant, used for tanks and industrial components.
- PETG: clear and tough, used where visibility or impact resistance matters.
- Polycarbonate: high impact strength combined with clarity.
- ASA/ABS: UV resistant, suited to outdoor and telecom applications.
Matching material to the job
The right choice depends on what the part must do: impact resistance, UV exposure, chemical contact, temperature range, or regulatory requirements. Hill Plastics forms all of the materials above and offers material selection guidance as part of design assistance, so engineers do not commit to a material before weighing the tradeoffs.
Bring your spec to the table
Tell the engineering team what the part needs to do, not just its dimensions. That context drives a better material recommendation and helps prevent costly field failures.
Ready to start?
Talk through your part with our engineering team
Share your drawings and we will recommend the process, material, and tooling approach that fits your project.
