Vacuum Thermoforming
At NEON.BG we offer vacuum thermoforming of plastic parts — from single samples and prototypes to serial production with subsequent CNC finishing. We use a GEISS machine for larger, deeper parts, as well as a compact machine for small elements, tests and short runs.
The technology is well suited to light, voluminous, functional parts with good surface quality, good repeatability, and the option for precise post-trimming. When needed, we handle the entire process — from mold design and manufacturing to forming, CNC finishing and a ready-to-use final part.
Forming molds are made on our 5-axis CNC machine, and finished parts then go through subsequent CNC finishing for precise contours and cutouts.
How we work
The process starts with a 3D model, a drawing, or a sample part. After a technical assessment, we choose the right material, forming method and mold type based on the geometry, batch size and requirements for the final product.
Once the mold is made, we form the part, and if needed carry out subsequent CNC finishing — 3-axis or 5-axis, depending on the complexity of the shape. This means the customer gets not just a formed element, but a finished, assembly-ready product.
What we can form
We form parts from a wide range of thermoplastics, including:
- ABS
- PVC
- HIPS
- PETG
- PMMA (acrylic)
- Composite and multi-layer materials
- ABS with decorative or technical coatings
This lets us produce both technical and design-oriented parts for a wide range of applications.
What parts we make
Vacuum thermoforming is well suited for:
- Panels and enclosures for machinery
- Covers and protective housings
- Technical and functional parts
- Prototypes and test batches
- Decorative elements and cladding
- Components for lighting and displays
- Transport and packaging forms
- Elements for equipment, interiors and specialized products
Molds for thermoforming
We design and produce different types of molds depending on the intended use and production volume.
MDF molds are well suited for prototypes, testing and short runs, when a more cost-effective solution and fast turnaround are needed.
Aluminum molds are well suited for higher repeatability, longer service life and serial production. When needed, they can be made with cooling channels for a more efficient and stable production cycle.
Choosing the right mold is key to the quality of the formed part, the material distribution, and the reliability of the production run.
Forming and subsequent finishing
After forming, parts often need precise trimming of contours, cutouts, mounting areas and technical lines. That's why, when needed, we carry out subsequent CNC finishing, including 5-axis trimming for more complex spatial shapes.
This enables:
- Precise finishing of the formed part
- Accurate positioning of cutouts and contours
- A better finish
- High repeatability
- A finished product, ready for assembly or the next operation
The combination of mold + forming + CNC finishing lets us offer a complete, integrated production process.
Technical specifications
Main GEISS machine
- Heating: top and bottom
- Heaters: infrared
- Process control: automated monitoring and adjustment
Compact machine
- Work area: 500 × 500 mm
- Forming depth: up to 250 mm
- Well suited for small parts, samples and short runs
Advantages of this service
- Well-suited technology for voluminous, lightweight parts
- Good surface quality and repeatability
- Suitable for prototypes, samples and series
- Molds made to your project's specifications
- Subsequent CNC finishing, including 5-axis
- A complete process — from idea to finished part
- Flexibility across different materials and applications
Where these parts are used
Vacuum-formed parts are used across many different fields — industrial equipment, machine building, interior and design solutions, displays, lighting, protective housings, transport forms, specialized enclosures and various technical applications.
This makes the technology suitable both for functional industrial products and for items with higher aesthetic requirements.
What to send us
A 3D solid model in STEP, Parasolid or SolidWorks format works best. We can also work with other 3D formats, but the file needs to be clean, at real scale, and free of stray points, lines, open surfaces or unnecessary nodes.
If you don't have a 3D model yet, we can start from a drawing, sketch, dimensioned photo, or an existing part.
Frequently Asked Questions
What's the maximum sheet thickness you can form?
Up to 12 mm on the main GEISS machine, with a forming depth of up to 700 mm.
Do you make the mold, or do I need to provide one?
We make the mold to match your project — MDF for prototypes and short runs, or aluminum for serial production with higher repeatability.
Do you do finishing work after forming?
Yes — subsequent CNC finishing (3- or 5-axis) for precise contours, cutouts and mounting areas.
Have a project with several steps? See how we handle it with our "Turnkey Project" service — a complete solution from idea to finished product.