In the field

Parts we've engineered

Real programmes across EV, robotics, medical, appliances, energy storage and export — from drawing to dispatch. Customer names are held in confidence; the engineering is exactly as it ran.

Body panels for an electric two-wheeler

Challenge: A fast-scaling EV maker needed durable, UV-stable exterior body panels without the cost and 4-month lead time of injection-mould tooling — and needed to iterate the styling between early production batches.
Solution: Thermoformed UV-stable ASA panels, colour-matched in-house from our own extruded sheet, with soft tooling cut on our 5-axis CNC in about four weeks. Design revisions were absorbed on the soft tool at negligible cost.
Result: A faster market launch, a lighter vehicle and a repeatable premium finish across production runs — at a fraction of the tooling capital an equivalent injection programme would have locked up.

~4 wks

to first panels

10–20%

of IM tooling cost

ASA

UV-stable, colour-fast

Impact-resistant covers for autonomous mobile robots

Challenge: An AMR manufacturer needed precise sensor cut-outs, genuine impact resistance and a premium high-gloss finish in an FR-capable material — with glass-fibre enclosures proving heavy, slow and costly.
Solution: ABS-PMMA thermoformed covers with UL 94 FR options, 5-axis CNC-trimmed to tight tolerances with datum-referenced sensor apertures for pick-and-place assembly.
Result: A lighter, more cost-effective alternative to glass-fibre, ready for volume, with the premium surface finish the product brand required.

ABS-PMMA

gloss + impact

±0.5 mm

trimmed apertures

UL 94

FR options

ESD-safe enclosures for a medical OEM

Challenge: A device manufacturer needed dimensionally stable, ESD-safe housings compatible with a sterile workflow, and needed them to clear OEM validation without iteration.
Solution: PC-FR thermoformed enclosures, datum-referenced and inspected on our 8-gate line with full traceability — COA, MTC and PPAP-level documentation supplied with first articles.
Result: Consistent, compliant parts that cleared OEM validation first time, moving the programme into a repeat supply relationship.

PC-FR

V-0 + ESD

First-time

validation pass

Full

COA / MTC / PPAP

Refrigerator liners in ESCR-grade HIPS

Challenge: An appliance manufacturer needed deep-drawn inner liners that resist the stress-cracking caused by refrigerant blowing agents, hold dimensional stability over a long service life and meet food-contact rules.
Solution: Thick-gauge thermoforming in our own ESCR + FDA-grade HIPS (StellarEx HIPS Cool), with plug-assisted forming to hold wall thickness through the deep draw.
Result: Durable, moisture-resistant liners with consistent walls and a clean matte finish, produced from sheet we extrude ourselves for full grade control.

HIPS Cool

ESCR + FDA

Deep draw

plug-assisted

In-house

sheet extrusion

Charging-station & power-electronics housings

Challenge: A charging-network builder needed weatherable, FR-grade enclosures for EV chargers and power electronics — produced faster and cheaper than sheet metal as the network scaled across sites.
Solution: Thermoformed housings in UV-stable, flame-retardant grades with formed-in mounting features, sealed seams and colour-matched finishes — tooled in weeks, not months, on customer-funded soft tooling.
Result: A durable, safe, brand-consistent enclosure at a fraction of metal-fabrication cost and lead time — ready to scale with the charging network.

FR-grade

UL 94 options

Weeks

to first tooling

UV-stable

outdoor-rated

Large protective covers for a US instrumentation OEM

Challenge: A US instrumentation OEM needed large, rugged HDPE protective covers with the consistency and documentation of a domestic supplier — delivered reliably across an ocean, programme after programme.
Solution: Heavy-gauge thermoformed HDPE covers produced at our Umbergaon plant (20 km from Vapi, near Nhava Sheva port), with export-grade packing, stacking-optimised nesting and full compliance documentation.
Result: A repeat, multi-year export relationship — proof that Indian thermoforming can meet US OEM standards on quality, packaging and delivery discipline.

Multi-year

repeat programme

HDPE

heavy-gauge

Export-grade

packing & docs

Sterile-barrier device trays for a European OEM

Challenge: A medical device maker needed clear, dimensionally exact device trays that seal to a Tyvek lid, survive gamma sterilisation and clear their sterile-barrier validation without iteration.
Solution: Cavities formed to the device CAD in medical-grade PETG, produced under cleanroom conditions with a seal flange matched to the customer’s lidding, supplied gamma-sterilised with FAIR and COA documentation.
Result: Trays that sealed and peeled to spec and passed sterile-barrier validation first time, moving the device into a repeat supply programme.

PETG

medical grade

Cleanroom

gamma-ready

First-time

validation pass

Static-safe handling trays for a semiconductor assembler

Challenge: An electronics assembler needed permanently static-dissipative trays with precise, repeatable pockets to protect sensitive assemblies through automated handling — without surface coatings that wear off.
Solution: Permanently static-dissipative ESD sheet, thermoformed with datum-referenced pockets and 5-axis CNC-trimmed so each cavity locates the assembly for pick-and-place.
Result: Consistent, humidity-independent ESD protection and repeatable pocket geometry that held up across high-cycle automated handling.

10⁶–10⁹ Ω

permanent ESD

Datum

located pockets

Automation

ready

Packaging — FMCG

Barrier trays for an FMCG food brand

Challenge: An FMCG brand needed food-safe trays with extended shelf life and a premium shelf presence, produced consistently across large promotional volumes.
Solution: Food-grade trays formed from our own extruded sheet — including EVOH-barrier PP for oxygen-sensitive products — colour-matched and textured in-house, with tooling sized for high-volume runs.
Result: Longer shelf life, consistent shade and finish batch to batch, and a supply chain simplified by sheet and forming under one roof.

Food-grade

FDA options

EVOH

barrier available

In-house

sheet + forming

Returnable dunnage for an auto Tier-1

Challenge: A Tier-1 supplier needed rugged, returnable dunnage trays to protect machined components in transit between plants, with nesting that maximised pack density on the return leg.
Solution: Heavy-gauge HDPE dunnage thermoformed with component-specific pockets and a nesting profile for empty return, trimmed to tight tolerances for line-side use.
Result: Fewer transit-damaged parts, denser return logistics and a durable tray that survives repeated closed-loop cycles.

HDPE

impact-tough

Nesting

return-optimised

Returnable

closed-loop

Twin-sheet pallets for a closed-loop supply chain

Challenge: A logistics operator wanted lightweight, hygienic, durable pallets to replace wood in a closed-loop system — strong enough to handle repeated racking without splinters or moisture uptake.
Solution: Twin-sheet thermoformed pallets — two sheets formed and fused into a rigid, hollow, double-walled structure — in tough HDPE, with a stackable, hygienic, moisture-proof design.
Result: A lighter, cleanable, long-life pallet that eliminated wood’s splintering and moisture problems in a returnable loop.

Twin-sheet

double-wall

HDPE

hygienic

Returnable

long-life

Nursery & hydroponic trays for a controlled-environment grower

Challenge: A controlled-environment grower needed dimensionally consistent nursery and hydroponic trays that resist UV and constant moisture and stack reliably for automated handling.
Solution: UV-stable, moisture-resistant trays thermoformed with consistent cell geometry and a stacking profile, formed from sheet extruded in-house for lot-to-lot consistency.
Result: Uniform cells for even germination, trays that survive wet, sunlit environments, and reliable stacking for automated lines.

UV-stable

moisture-proof

Uniform

cell geometry

Stackable

automation-ready

Branded counter displays for a retail rollout

Challenge: A brand needed product-specific counter displays with a premium, colour-matched finish, produced quickly and economically for a fast-moving promotional rollout in modest volumes.
Solution: Pressure-formed HIPS displays with product cradles and formed-in texture and colour, on soft tooling cut in-house in weeks and cheap to revise between campaigns.
Result: Sharp, on-brand displays delivered fast at a fraction of injection-mould tooling cost, with easy revisions between promotions.

Pressure-formed

sharp detail

Formed-in

colour & texture

Weeks

to shelf

Polycarbonate skylights & roof domes

Challenge: A building products company needed impact-resistant, UV-stable roof domes and barrel-vault rooflights that stay clear outdoors for years and cover large spans without metal tooling cost.
Solution: Large-format thermoformed polycarbonate domes and rooflights, formed on our large-bed lines with UV-protected grades and clean trimmed edges for glazing.
Result: Shatter-resistant, weatherable rooflights in large formats, produced without the tooling capital of alternative processes.

Polycarbonate

UV-stable

Large-format

domes

Shatter

resistant

FR interior panels for rail & transit

Challenge: A transit interiors supplier needed large, flame-retardant interior panels and trims that meet rail fire-safety expectations while keeping weight down and finish consistent.
Solution: Thick-gauge thermoformed FR-grade panels with formed-in texture, 5-axis CNC-trimmed to datum, formed on the large bed for oversized cabin components.
Result: Lightweight, FR-rated interior panels with a consistent finish, delivered at large-format sizes with repeatable trimming.

FR-grade

rail-rated

Large-format

panels

Lightweight

vs metal

ABS-PMMA shower trays converted from fibreglass

Challenge: A sanitary-ware maker’s hand-laid fibreglass trays were slow, inconsistent and needed gelcoat, sanding and paint — hard to scale with a consistent premium finish.
Solution: PMMA-ABS thermoformed trays and panels with a gloss, chemical-resistant acrylic cap, colour matched in the sheet and 5-axis CNC-trimmed to size — converting the FRP part to a repeatable formed part.
Result: A premium, easy-clean, repeatable part at higher throughput, with the gelcoat and paint operations removed and a styrene-free process.

PMMA-ABS

sanitary cap

Formed-in

colour

FRP

converted

Interior dashboard & door panels for a vehicle programme

Challenge: A vehicle programme needed large interior dashboard fascias and door trim cards with formed-in texture, integrated vents and precise instrument and speaker cut-outs — at a tooling cost and lead time injection moulding could not match for the volume.
Solution: Pressure-formed ABS panels with formed-in grain, 5-axis CNC-trimmed to datum for every aperture, colour-matched in-house so parts came off the tool finished.
Result: A cohesive interior set with a moulded-in texture and tight-fitting cut-outs, delivered on soft tooling in weeks with cheap revisions between iterations.

Pressure-formed

grained finish

Datum

cut-outs

Weeks

to tooling

Ducting & equipment covers for an HVAC maker

Challenge: An HVAC manufacturer needed large, lightweight ducting components and equipment covers with smooth airflow surfaces and louvred vents, produced without the cost of sheet-metal fabrication.
Solution: Thermoformed covers and duct components in tough, dimensionally stable grades, with formed-in louvres and mounting features, trimmed to fit the equipment.
Result: Lighter, corrosion-free covers with clean airflow surfaces that consolidated several fabricated pieces into single formed parts.

Lightweight

vs sheet metal

Formed-in

louvres

Corrosion

free

Signage & Advertising

3D letters & illuminated sign faces for a brand rollout

Challenge: A signage company needed deep, glossy 3D channel letters and embossed sign faces in consistent brand colours across a multi-site rollout, with weatherable outdoor performance.
Solution: Vacuum- and pressure-formed sign faces and letters in UV-stable, colour-matched sheet, with crisp embossing and clean trimmed edges for illumination.
Result: Bright, colour-consistent, weatherable signage delivered fast across sites, with tooling cheap enough to suit short branded runs.

UV-stable

outdoor

Colour-matched

brand

Fast

soft tooling

Fascias & housings for self-service kiosks

Challenge: A kiosk builder needed large, cosmetic fascias with screen and card-reader cut-outs, robust enough for public use and produced economically in modest, evolving volumes.
Solution: Pressure-formed fascias with formed-in texture and datum-referenced apertures for the screen, reader and buttons, 5-axis CNC-trimmed for repeatable fit.
Result: A premium, durable kiosk front produced at low tooling cost, with revisions absorbed cheaply as the design evolved between deployments.

Pressure-formed

cosmetic

Datum

apertures

Low-volume

friendly

Food Service

Cups, dome lids & trays for a food-service brand

Challenge: A food-service brand needed clear cups, dome lids and trays that are food-safe, stack and denest reliably on high-speed lines, and carry a premium clear-shelf presence.
Solution: Thin-gauge thermoformed APET and PP formed from our own extruded sheet, with denest features and consistent gauge for high-speed automated filling.
Result: Glass-clear, food-safe packaging that runs reliably at speed, with consistent shade and stacking from sheet controlled in-house.

Food-grade

APET / PP

Denest

high-speed

In-house

sheet

Diagnostic kit trays & blisters for an IVD maker

Challenge: An in-vitro diagnostics maker needed clear kit trays and blisters holding vials, a reader and droppers in precise cavities, sealable to a lidding film and clean enough for the product.
Solution: PETG blisters and kit trays formed to the component CAD with located cavities and a seal flange, produced under controlled conditions with full material traceability.
Result: Kits that present and protect every component, seal reliably, and cleared incoming quality with COA and inspection documentation.

PETG

clear, sealable

CAD

located cavities

Traceable

COA / FAIR

Modular display & exhibition panels for a retail programme

Challenge: A retail brand needed modular exhibition and display panels with product cradles and a premium finish, produced quickly for a rolling campaign in modest volumes.
Solution: Pressure-formed display shells and panels with formed-in colour, texture and product-specific cradles, on soft tooling cut in-house and cheap to revise per campaign.
Result: On-brand, reconfigurable display modules delivered fast at a fraction of injection-mould tooling cost, refreshed easily between campaigns.

Pressure-formed

premium

Product

cradles

Campaign

agile

Clear diffusers & light covers for a lighting OEM

Challenge: A lighting OEM needed optically clear diffusers and dome covers with even light spread and outdoor UV stability, in large formats that avoided expensive tooling.
Solution: Thermoformed acrylic (PMMA) and polycarbonate diffusers and domes, formed for even wall thickness and clean optical surfaces, with UV-stable grades for exterior fittings.
Result: Clear, even-diffusing, weatherable light covers in large formats, produced without the tooling capital of alternative processes.

Acrylic / PC

optical

Even

diffusion

UV-stable

outdoor

Cabin panels & cowls for agricultural equipment

Challenge: An agricultural equipment maker needed rugged, UV- and weather-stable cabin panels and engine cowls that survive the field, in the modest volumes typical of off-highway machines.
Solution: Thick-gauge thermoformed ASA/ABS panels with formed-in texture, 5-axis CNC-trimmed, tooled economically for off-highway volumes — a lighter, rust-free alternative to metal or fibreglass.
Result: Durable, weatherable panels that hold colour in the field, produced faster and lighter than the fabricated parts they replaced.

ASA / ABS

weatherable

Off-highway

volumes

Lighter

vs metal

Rugged housings for UAV & defence electronics

Challenge: A defence-electronics supplier needed rugged, lightweight equipment and UAV housings with precise cut-outs and an FR-capable, impact-resistant material, at low-to-medium programme volumes.
Solution: Thermoformed housings in impact-resistant, FR-capable grades with datum-referenced cut-outs and secure mounting features, 5-axis CNC-trimmed for repeatable assembly.
Result: Lightweight, rugged housings meeting the programme’s impact and fire requirements, produced at low tooling cost for the volume.

FR-capable

impact-tough

Datum

cut-outs

Lightweight

rugged

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