For more than 67 years, Jamestown Plastics has helped manufacturers match materials to part requirements across industries. Internal design support, in-house tooling, and decades of application knowledge give customers a clearer path to durable, reliable thermoformed components. Read on to explore the most commonly used materials in thermoforming and how they support real-world performance.
What Materials Can Be Thermoformed?
Many thermoplastics can be shaped through the thermoforming process. Each material offers a distinct balance of rigidity, impact performance, chemical resistance, and appearance. The best option depends on how the finished part will be used, the environment it must withstand, and the compliance requirements of the application.
Jamestown Plastics works with a wide variety of materials to support everything from returnable packaging trays to rugged shrouds, consumer packaging, industrial housings, and protective storage systems.
Common Plastics Used in Thermoforming
High Impact Polystyrene (HIPS)
HIPS offers a strong mix of stiffness and cost efficiency, making it a popular option for high-volume industrial trays, dividers, and handling systems. Its smooth surface also supports precision features used in automated assembly lines.
ABS
ABS combines rigidity with impact resistance. This balance is ideal for enclosures, equipment housings, and automotive interior components that require dimensional stability and dependable durability. Textured and colored options support both functional and aesthetic goals.
PETG
PETG is valued for its clarity, toughness, and formability. It works well for packaging, medical transport trays, visual displays, and protective covers. The material holds tight tolerances and accepts diecutting and sealing processes often used in medical and laboratory environments.
Polycarbonate
Polycarbonate handles demanding conditions with its exceptional impact strength and heat resistance. It supports heavy-duty industrial applications, machine guards, and protective covers. Its optical-grade clarity also makes it suitable for transparent components.
HDPE
HDPE resists chemicals, moisture, and impact. These qualities make it a dependable choice for reusable packaging, dunnage trays, protective totes, and containers exposed to repetitive handling or corrosive environments.
Polypropylene (PP)
PP provides excellent fatigue resistance and is commonly used for hinged components, reusable industrial trays, and lightweight packaging. Its chemical resistance is useful in controlled environments and applications that involve cleaning procedures.
Thermoplastic Polyolefin (TPO)
TPO materials bring durability and weatherability, supporting exterior components such as automotive trim, covers, and equipment housings. It performs well in outdoor conditions and retains structural integrity over long use cycles.
Autoclavable Polysulfone
Certain medical applications require materials that withstand high temperatures and sterilization cycles. Polysulfone supports reusable medical trays, transport systems, and components exposed to demanding cleaning processes.
Conductive and Anti-Static Materials
Electronics and sensitive components call for electrostatic protection. Conductive, anti-static, and ESD-safe plastics help maintain compliance standards and protect assemblies during storage, handling, and shipping.
Recycled and Sustainable Material Options
Sustainability continues to influence material programs throughout manufacturing. Recycled content, regrind options, and recyclable polymers support waste reduction goals without sacrificing performance. Jamestown Plastics collaborates with customers to evaluate sustainable alternatives that align with performance, compliance, and cost targets.
Additional Thermoforming Materials Available
Jamestown Plastics also supports a broader range of materials for projects that require specific mechanical, thermal, or aesthetic properties. These options expand design flexibility and help manufacturers match performance needs across diverse environments. Available materials include:
- APET and RPET for strong, lightweight, and recyclable packaging applications.
- PVC, polyurethane, and nylon-based materials used in components that call for flexibility, resilience, or higher heat resistance.
- ABS/vinyl alloys such as Royalite® and KYDEX® for parts that benefit from enhanced impact performance or flame resistance.
- High-performance polymers including PTFE, Delrin, and UHMWPE for demanding chemical, wear, or low-friction environments.
- Specialty coatings and films such as decorative laminates, oxygen-barrier materials, flocked surfaces, and UV-protective layers for targeted functional and visual requirements.
These materials supplement the core options used in most thermoformed components and offer customers additional pathways to meet exact performance expectations.
How Jamestown Plastics Helps Match Materials to Applications
Material selection is not a one-size-fits-all decision. Jamestown Plastics evaluates functional requirements, part geometry, handling conditions, and regulatory considerations before recommending a resin. In-house design engineering, tooling, and trimming capabilities add another layer of consistency, keeping projects aligned with performance expectations throughout production.
Each project benefits from a structured development process that incorporates manufacturability, durability, and long-term reliability. From industrial handling trays to complex housings and protective packaging solutions, materials are chosen for their real-world performance, not guesswork.
Takeaways
Material choice plays a major role in how a thermoformed part performs over time. The wide range of available plastics gives manufacturers options for strength, clarity, durability, environmental resistance, and cost. Jamestown Plastics supports customers through that selection process with experience across industries, in-house tooling, and a clear understanding of how each material behaves in real applications. The goal is straightforward: components that meet requirements and hold up in use.
Have questions about thermoforming materials? Connect with Jamestown Plastics today to get started.
