Thermoforming

We design and manufacture precision-engineered thermoformed solutions for lightweight, durable, and highly customizable cases and enclosures. Using advanced vacuum and pressure thermoforming technology, we shape high-impact materials like ABS, polycarbonate, and polyethylene into rigid, protective cases with precise contours and reinforced edges. Our process allows for thin yet strong walls, intricate designs, and cost-effective large-scale production, making it ideal for medical, military, electronics, and industrial applications. With custom branding, seamless enclosures, and tailored interior configurations, our thermoformed solutions provide superior protection and design flexibility to meet your exact specifications.

vacuum forming machine
Royal Case blue crown logo
Thermoforming

Thermoformed to Perfection

Discover the strength, precision, and customization of our thermoforming solutions, built to protect, engineered to perform.
vacuum formed medical product tray

High-Precision Custom Molding

Our vacuum formed interiors and components provide lightweight, semi-rigid protection with a sleek finish. We create custom-fit pieces ideal for medical, electronics, and consumer applications. Using custom vacuum formed interiors provides your product with enhanced protection and and elevated look.

Components & Enclosures

We manufacture precision-molded components and enclosures tailored to complex product designs. With CNC-machined mold development and in-house design, we produce parts that ensure structural integrity and seamless integration into electronic, automotive, and industrial applications.
thermoformed plastic tray
stacked atwt cases in a warehouse

High-Volume Production

With 15 global manufacturing sites, we offer cost-effective, high-volume injection molding capabilities to support large-scale production needs. Our automated processes allow for consistent quality, rapid turnaround times, and efficient manufacturing, ensuring that your products are delivered on time and to exact specifications, no matter the scale.

In-House Mold Production

Unlike other manufacturers, we own our mold fabrication and repair process. With no middleman, custom molded cases are accessible by saving you development time and cost.
Vacuum forming mold

Ready for a Test Run?

Request A Sample
Royal Case white crown logo
The Royal Treatment

DESIGNED. DEVELOPED. DELIVERED.

A dedicated project manager is with you every step of the process, creating a seamless, efficient experience.
Orange right arrow

DESIGN CONSULTATION

Collaborate with Royal Case's experienced specialists to design a custom case tailored to your specific needs.
Orange right arrow
PROTOTYPE
Receive a working prototype of your custom case, allowing you to evaluate and approve the design before full-scale production begins.
Orange right arrow
PRODUCTION
Upon approval, your custom case enters production, utilizing our extensive manufacturing capabilities to ensure the highest quality output.
Orange right arrow
INSPECTION
Your order undergoes rigorous quality control checks to meet every standard, ensuring durability and functionality.
Orange right arrow
DELIVERY
Finished products are stored in our expansive warehousing facilities and shipped to your specified location, ensuring timely and efficient delivery.

BLOG: Thermoforming

Everything you need to know about thermoforming..