Full-Service Capabilities
From Design Support to Final Assembly — All In-House
At Blue Ridge Thermoforming, we are a true one-stop partner for custom thermoformed plastic solutions. From initial design through tooling, production, precision trimming, assembly, and fulfillment, every step is handled in-house at our Greenville, SC facility.
This full vertical integration gives you faster lead times, tighter quality control, lower costs, and a seamless experience from concept to delivered parts.
Our Core Capabilities
Every capability under one roof for seamless project execution
Rotary Thermoforming
High-speed, continuous heavy-gauge rotary thermoforming with exceptional precision and repeatability.
Our three large-format rotary thermoformers handle forming areas up to 60″ × 100″ and material thicknesses from .030″ to .500″. Whether you need durable equipment covers, industrial trays, or large custom components, our process ensures consistent wall thickness, sharp detail, and superior part quality.
- Forming areas up to 60″ × 100″
- Material thickness .030″ – .500″
- Consistent wall thickness
- Superior part quality
5-Axis CNC Trimming
Get assembly-ready parts with tight tolerances every time.
Our advanced 5-axis CNC routers provide precise trimming, drilling, and routing on even the most complex thermoformed shapes. This in-house capability eliminates secondary operations, reduces lead times, and ensures your parts fit and function perfectly right out of the box.
- Precise trimming and drilling
- Complex shape capability
- Eliminates secondary operations
- Assembly-ready parts
In-House Tooling
Fast turnaround from prototype to production.
We design and build high-performance tooling in-house or through trusted partners. Our tooling solutions are engineered for durability (millions of cycles) and optimized for your specific production volume and part requirements.
- Machined thin-gauge tools
- Cast aluminum heavy-gauge tools
- 5-axis router fixtures
- Check fixtures and assembly jigs
Assembly Services
Complete packaging and fulfillment solutions.
Beyond forming and trimming, we offer full secondary assembly, kitting, packaging, and fulfillment services. From simple hardware insertion to complex multi-component assemblies and custom packaging, we deliver finished, ready-to-ship products that save you time and reduce your supply chain complexity.
- Hardware insertion
- Multi-component assembly
- Custom packaging
- Fulfillment services
Common Materials
We work with a comprehensive range of thermoplastic materials to meet your exact requirements:
All materials can be customized for UV resistance, chemical resistance, ESD protection, or specific color matching.
Climate-Controlled Clean Room
Thin-gauge parts are packaged in a climate-controlled clean room environment — ideal for sensitive electronics, medical, and industrial components.
This controlled environment ensures your parts remain pristine from production through delivery.
Ready to Experience True Full-Service Thermoforming?
One partner. Every capability. Delivered on time.