Northern Indiana Since 1982 Call: (574) 264-2143 Fax: (574) 262-8208
100% Employee Owned

Design & Engineering Excellence

From concept to production, our engineering team delivers innovative thermoforming solutions optimized for quality, cost, and manufacturability

Engineering Partnership You Can Trust

Our experienced engineering team works as an extension of your design department, bringing decades of thermoforming expertise to every project. We understand the unique challenges of vacuum forming and heavy gauge thermoforming, ensuring your designs are optimized for both performance and production efficiency.

Whether you're converting an existing design from another manufacturing process or developing a new product from scratch, we provide the technical expertise and creative problem-solving needed to bring your vision to life.

Start Your Project
CAD Design Engineering

Our Engineering Process

A systematic approach ensures optimal results at every stage

1

Concept Development

Initial consultation to understand your requirements, application, and goals. We review specifications and develop preliminary concepts.

2

3D CAD Modeling

Creation of detailed 3D models using SolidWorks, optimized for thermoforming with proper draft angles, radii, and wall thickness.

3

Design for Manufacturing

DFM analysis to ensure efficient production, identifying potential issues and optimizing for cost and quality.

4

Prototype Development

Rapid prototyping for design validation, fit checks, and functional testing before committing to production tooling.

5

Tool Design

Custom tooling design optimized for part quality, cycle time, and longevity using aluminum, composite, or wood materials.

6

Production Support

Ongoing engineering assistance through production launch, including troubleshooting and continuous improvement.

Engineering Capabilities

3D CAD Modeling

3D CAD Design

  • SolidWorks 3D modeling
  • Parametric design capabilities
  • Surface modeling
  • Assembly design
  • Photo-realistic rendering
Reverse Engineering

Reverse Engineering

  • 3D scanning services
  • Point cloud to CAD conversion
  • Legacy part documentation
  • Design improvements
  • Tool recreation
FEA Analysis

Analysis & Simulation

  • Finite element analysis
  • Stress & load testing
  • Thermal analysis
  • Material flow simulation
  • Warpage prediction
Value Engineering

Value Engineering

  • Cost reduction analysis
  • Material optimization
  • Part consolidation
  • Assembly simplification
  • Weight reduction
Rapid Prototyping

Rapid Prototyping

  • Quick-turn prototypes
  • Functional testing samples
  • Fit & form validation
  • Design iteration support
  • Pre-production samples

Software & Technology

Industry-leading design and engineering software platforms

SW
SolidWorks
AC
AutoCAD
MC
Mastercam
3D
3D Scanning
FEA
FEA Software
CAM
CAM Systems

Design for Manufacturing Excellence

Our DFM approach ensures your parts are optimized for the thermoforming process from the beginning, avoiding costly design changes and production delays.

We analyze every aspect of your design to identify opportunities for improvement:

  • Proper draft angles for easy part removal
  • Optimal wall thickness distribution
  • Strategic placement of forming features
  • Elimination of undercuts where possible
  • Material utilization optimization
  • Secondary operation minimization
DFM Analysis Process

File Formats We Accept

.SLDPRT .SLDASM .STEP .IGES .STL .DWG .DXF .PARASOLID .PDF .OBJ

Secure FTP available for large file transfers • NDA protection standard

Ready to Optimize Your Design?

Our engineering team is ready to help transform your concepts into production-ready thermoformed solutions. Contact us today for a free design consultation.

Request Engineering Support Learn About Prototyping