What Heavy Gauge Thermoforming Brings to the Table
Heavy gauge thermoforming involves forming plastic sheets thicker than .060” into durable, structural parts. These components often replace metal or fiberglass, offering a lighter, corrosion-resistant alternative that holds up in demanding environments. Common applications include equipment housings, reusable transport trays, automotive panels, and industrial enclosures.
Unlike thin gauge thermoforming, which focuses on high-volume packaging and lightweight products, heavy gauge forming is ideal for lower to mid-volume runs that require robustness, clean aesthetics, and functional performance. It’s well suited for applications where strength and longevity matter.
Rotary Thermoforming: High Output Meets Large Scale
Jamestown Plastics’ rotary thermoforming systems streamline the production of large plastic parts with greater speed and accuracy. This multi-station process keeps material moving through heating, forming, cooling, and trimming stages in a continuous cycle. As a result, customers benefit from faster cycle times and consistent quality across each part.
Parts up to 5 feet by 9 feet can be thermoformed using our rotary and single-station equipment. Deep-draw capabilities and complex contours are no problem. From oversized industrial trays to full-scale automotive components, our rotary forming setup makes it possible to achieve impressive dimensions without losing dimensional integrity.
Full Project Control Starts In-House
Total project control begins long before the first sheet hits the forming machine. Our in-house design and tooling capabilities allow us to develop custom molds quickly while dialing in exacting specifications. This approach minimizes delays, simplifies revisions, and delivers tighter tolerances from the start.
Once parts are formed, robotic trimming technologies take over. With 5-axis routers, laser cutters, and water jet systems, we execute precise cuts, openings, and edge treatments, even on irregular surfaces. The result is a cleaner, more consistent finish and less need for secondary operations.
Material Flexibility for Demanding Applications
A wide variety of materials are available for heavy gauge forming. Jamestown Plastics works with everything from ABS and HDPE to polycarbonate, TPO, and specialty vinyl alloys like Royalite™ and Kydex™. Some materials are selected for their UV stability or flame resistance, while others offer chemical resistance, impact strength, or long-term outdoor durability.
Material gauges range from .060” to .500”+, giving us the flexibility to meet the structural requirements of each application. Need something more sustainable? We also support recycled and biodegradable materials when your project calls for an environmentally responsible option.
Built for Big Jobs Across Industries
Large-format thermoformed parts show up in a wide range of industries, and our team is equipped to support them all.
In automotive manufacturing, heavy gauge components like bumper guards, interior panels, and returnable trays play a key role in production and logistics. For medical applications, reusable carts, housing panels, and sterile storage systems require precision and cleanable finishes. Electronics and industrial customers turn to us for protective housings, custom enclosures, and ESD-safe materials to shield sensitive equipment.
Every project is different, but the core expectations – quality, fit, and durability – remain the same.
Domestic Manufacturing in a Shifting Trade Environment
With ongoing tariff pressures and evolving trade policy, sourcing from domestic manufacturers has never been more important. Jamestown Plastics operates entirely in the United States, with facilities in New York, Pennsylvania, and Texas. Customers avoid costly import fees and long shipping timelines while gaining a responsive manufacturing partner closer to home.
Made in the USA means more than location – it reflects our commitment to supporting American industry, strengthening customer supply chains, and maintaining high standards in every phase of production. As global sourcing grows more complex, working with a domestic partner offers peace of mind and long-term value.
Experience, Patents, and Practical Problem Solving
Every solution we provide is shaped by decades of real-world experience and a relentless drive to improve. Jamestown Plastics holds more U.S. utility patents than any other company in the thermoforming space, a reflection of the way we approach challenges. The goal isn’t to do it how it’s always been done; it’s to find the smartest way to do it better.
Our team thrives on complexity. From design to final shipment, each stage of production is handled with care and technical depth. It’s how we help customers launch new programs, solve packaging challenges, and bring durable plastic parts into the field with confidence.
Ready to Talk Large Part Thermoforming?
When it comes to heavy gauge thermoforming, Jamestown Plastics brings the right mix of scale, expertise, and flexibility. We form large parts with speed and accuracy, using materials and methods that align with your performance and sustainability goals.
Start the conversation today and let’s discuss how our rotary forming and large-item capabilities can support your next project.
