Where Thermoforming Fits in a Modern Manufacturing Landscape: Industry Expertise from RapidMade’s Micah Chaban
Introduction
In the world of advanced manufacturing, few companies have carved out a niche as effectively as RapidMade. Founded with a mission to bridge the gap between custom manufacturing and cost-effective production, the company specializes in thermoforming, additive manufacturing, and CNC machining. With a strong focus on design for manufacturability (DFM), RapidMade helps businesses optimize their production processes, reduce costs, and improve efficiency.
At the heart of RapidMade’s success is Micah Chaban, the company’s Vice President of Sales and a driving force behind its growth. With years of experience in manufacturing, sales, and engineering, Micah has helped businesses navigate the complexities of thermoforming—from material selection and mold design to precision trimming and finishing.
In this interview, Micah shares his insights on why thermoforming remains one of the most versatile manufacturing methods, the biggest design mistakes companies make, and how emerging technologies and sustainability efforts are shaping the future of the industry.
Thermoforming has been around for a long time, but it’s still a go-to manufacturing method. What makes it such an attractive option for today’s industries?
Thermoforming offers an incredible balance of cost, speed, and scalability, which is why it’s still a preferred manufacturing process across industries like medical, aerospace, industrial equipment, and consumer goods. Compared to other manufacturing methods, it has significantly lower tooling costs and faster turnaround times.
For companies that don’t need the extreme precision of injection molding but still want a high-quality, durable plastic part, thermoforming is an ideal choice. It allows for large parts, complex geometries, and relatively quick production cycles, all while keeping costs much lower than other forming methods.
Compared to injection molding, CNC machining, or 3D printing, where does thermoforming have the biggest advantages?
Each process has its place, but thermoforming is uniquely positioned for medium- to high-volume production where cost efficiency is a priority. Compared to injection molding, thermoforming has significantly lower mold costs and shorter lead times. If a company only needs a few thousand parts, investing in an injection molding tool that costs tens or hundreds of thousands of dollars doesn’t make sense.
Compared to CNC machining, thermoforming is simply faster and more material-efficient. Machining is great for high-strength parts but can be slow and expensive, whereas thermoforming reduces material waste and enables faster cycle times.
As for 3D printing, it’s excellent for prototyping and low-volume, highly complex parts. But when you need scalability and affordability, thermoforming is far superior.
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Many companies struggle with material selection. What are the key factors to consider when choosing a thermoforming plastic?
Material selection is one of the most critical decisions in thermoforming. There are a few key factors to consider:
- Durability & Impact Resistance – Will the part need to withstand high impacts or wear and tear? ABS and polycarbonate are great for toughness, while HIPS and PETG are more affordable for less demanding applications.
- Heat & Chemical Resistance – If the part needs to handle high temperatures or exposure to chemicals, materials like polypropylene (PP), Kydex, or polycarbonate (PC) are great options.
- Transparency vs. Opacity – For medical trays, food packaging, or clear protective covers, PETG and polycarbonate are ideal. For industrial enclosures or automotive panels, opaque materials like ABS or HIPS work better.
- Regulatory Compliance – In food-safe or medical applications, materials must be FDA-compliant. PETG and certain grades of HIPS and PP meet these standards.
Ultimately, the material choice should balance cost, performance, and manufacturing feasibility. At RapidMade, we help customers select the best material for their application based on these criteria.
What are some of the biggest design mistakes engineers make when preparing a part for thermoforming?
One of the most common mistakes is not accounting for draft angles. In thermoforming, the part needs to release cleanly from the mold, and without proper draft angles (3–5° for male molds, 1–2° for female molds), parts can get stuck or warped.
Another big issue is ignoring material thinning. Thermoforming stretches plastic over a mold, so areas with deep draws or sharp corners will naturally become thinner. If this isn’t accounted for in the design phase, parts can fail under stress or lack uniform strength.
Companies also underestimate how much mold selection impacts cost and quality. A poorly designed mold can lead to inconsistent parts, unnecessary trimming waste, or long cycle times. Working with a partner like RapidMade, who understands DFM, can prevent these costly mistakes.
How does mold selection impact production costs and quality, and what should companies look for when deciding on tooling?
Molds determine the accuracy, durability, and efficiency of the entire process, so getting the right mold is crucial. Companies should consider:
- Production Volume – For low-volume runs, urethane or composite molds work fine, but for high-volume production, machined or cast aluminum molds are the best choice.
- Cooling Efficiency – Mold cooling impacts cycle time and consistency. Water-cooled aluminum molds allow for faster production and better repeatability.
- Surface Finish Requirements – If a product requires a smooth, high-gloss surface, investing in a polished aluminum mold is necessary. For textured finishes, cast aluminum with an etched or sandblasted surface works well.
RapidMade helps customers choose the most cost-effective mold material based on budget, volume, and finish requirements.
Trimming and finishing are often overlooked but are critical to final part quality. What are the best practices for achieving precision in this stage?
Trimming is just as important as the forming process itself. A part can be perfectly formed, but if the trimming is off by even a few millimeters, it can cause fitment issues, sharp edges, or aesthetic defects.
For high-precision parts, we always recommend CNC trimming, which provides repeatability and accuracy down to ±0.015 inches. Hand trimming is fine for prototyping, but for consistent quality in production, automated trimming is the way to go.
Another key factor is proper fixture design—if the part isn’t securely held during trimming, it can lead to misalignment and inconsistent cuts.
Why should a company choose RapidMade for their thermoforming needs? What sets you apart in the industry?
At RapidMade, we focus on end-to-end manufacturing solutions. We don’t just form parts—we optimize designs for manufacturability, help clients choose the best materials, and ensure precision trimming and finishing.
We also leverage cutting-edge technologies like CNC machining, 3D scanning, and digital manufacturing tools to improve accuracy and reduce lead times. Many companies just offer thermoforming, but we provide a full-service approach, from prototyping to full-scale production.
Finally, we take pride in working closely with our customers. Whether it’s small startups or Fortune 500 companies, we tailor solutions to meet their unique needs, budget, and production goals.
Get Precision Thermoforming with RapidMade
If you’re looking for high-quality, cost-effective thermoforming solutions, RapidMade can help. From custom tooling and material selection to precision trimming and finishing, we provide end-to-end support to ensure your parts meet the highest standards of quality and performance.
📩 Email: info@rapidmade.com
🌐 Website: rapidmade.com
By choosing RapidMade, you’re not just getting a manufacturer—you’re getting a trusted partner in advanced thermoforming.
