Pressure Formed Plastic

Highl Detailed Plastic Parts

Inexpensive Small Runs

Made in the USA

Pressure Formed Plastic Parts

ICS provides high quality, affordable plastic pressure forming services for a wide range of industries and applications.

We provide engineering and design support, ensuring your plastic parts are manufactured in the most cost-effective way, without compromising your project requirements. When it comes to plastic manufacturing, we often recommend pressure forming to our customers due to its scalability and low cost relative to other production methods. Pressure forming is well suited to medium and large plastic parts and can be applied to a wide range of production volumes. Although pressure forming is one of our most requested manufacturing processes, we also offer other plastic themoforming services – so no matter what process suits your project best, ICS has you covered.

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Pressure Formed Plastic Manufacturing

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Plastic Pressure Forming Process

Pressure forming is a manufacturing process commonly used with plastics to form complex, highly detailed shapes. In this process pressure is applied to heated plastic to force it into a mold to produce a finished part. Although this process is similar to vacuum forming, the addition of pressure on one side of the material during the forming stage greatly increases the overall force applied during production, allowing for much finer detail in the mold. This results in a finished plastic part that is nearly indistinguishable from an injection molded plastic part, at a much lower cost. In addition to the quality of the finished product, this process also lends itself to lower production volumes, making it perfect for projects where injection molding is isn’t an option. If you’re not sure what the plastic manufacturing process is right for your part, contact us today and our engineers will work with you to make sure the job is done right. 

Benefits of Pressure Formed Plastic

Pressure formed parts can be produced with sharp details and complex textures. Parts with aesthetically pleasing vents, ports, lettering, textured surfaces, logos, and other imagery can all be produced by this process. These benefits can be applied to parts of varying sizes, allowing for high quality, large form factor parts to be produced quickly and inexpensively. Most common thermoplastic materials can be used, giving you a high degree of control over the final colors, textures, and structural properties of your plastic part. The combined benefits of this manufacturing process make it a fantastic alternative to injection molding for medium volume production runs.

Thermoplastic Materials

Whether you’re at the stage in your project where you know exactly what material you want to use, or you’re just starting the planning process, it’s helpful to know what options are available for each manufacturing process. A variety of plastics can be used in pressure forming, each with their own unique impacts on your finished part.

Thermoplastics we commonly work with include (but are not limited to):


Acrylic is a very sturdy material that is well suited to a variety of applications, and in many cases is a suitable alternative to glass.


Acrylonitrile butadiene styrene (ABS) is light weight, impact resistant, and poses few health risks under normal use conditions. This makes ABS ideal for parts that may be handled frequently or roughly, such as consumer products or appliances.


High-density polyethylene (HDPE) is an inexpensive, chemical-resistant plastic that is also recyclable. Although it is commonly used in disposable products such as chemical containers and consumer packaging, it can also be used for permanent parts. 


Nylon is a “polyamide”, a class of polymer that is found in everything from fabrics and ropes to mechanical components. Pressure formed nylon is a good fit for handheld or desktop tool cases, among other uses.


Polylactic acid (PLA) is a compostable thermoplastic that is produced  from renewable resources. It is often used in 3D printing, but can also be pressure formed to produce a much higher quality part.


Polyphenylene oxide (PPO) is a high strength plastic with good resistance to heat distortion. It is resistant to stress cracking, weathering, and most chemicals.


Polystyrene (PS) is cheap, rigid, transparent, and is used in a variety of products, from test tubes to solo cups. When pressure formed, polystyrene can form more complex and detailed shapes, making it ideal for industrial electronics housings or high-end cosmetic packaging.  


Polyvinyl chloride (PVC) is the third most widely produced synthetic plastic polymer in the world. PVC is often associated with pipes, but it is often used in medical and industrial applications as well. PVC is impact resistant, non conductive, and chemical resistant, making it ideal for electronics and hospital equipment.

ICS has extensive experience selecting the best thermoplastic for a particular use case. If you’re not sure what material is best for your part, please contact us – we’d love to talk over your requirements and find the plastic best suited to your needs.

Why Choose ICS for Pressure Formed Plastic Manufacturing?

Located in Rochester, NY, ICS produces the parts you need at prices that are competitive with overseas manufacturers – with none of the hassle associated with non US-based production. We pride ourselves on making the manufacturing process the easiest part of your project. Our customer service is second to none, and our knowledgeable engineers will work with you from start to finish to ensure your components are produced on time and up to spec.  Contact us today, and we’ll get to work to ensure the success of your project.  

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