Our Process
Precision. Performance. Partnership.
At Blue Ridge Thermoforming, we deliver high-quality custom thermoformed plastic solutions through a streamlined, collaborative process that emphasizes innovation, precision engineering, and customer success.
With over 30 years of experience, we guide your project from initial concept through design, prototyping, tooling, and full-scale production.
End-to-End Custom Thermoforming Process
Design & Development
Our expert design team specializes in creating custom vacuum-formed and thermoformed solutions optimized for pack density, product protection, user functionality, and cost efficiency.
Using SolidWorks 3D modeling software, we develop detailed designs that allow real-time collaboration and design reviews with your team before any prototyping or tooling begins.
Prototyping
Validate your design quickly and affordably before committing to production tooling.
We produce up to 50 prototype parts using wood or composite molds, giving you physical samples to test fit, function, and performance.
Tooling
Durable, high-performance tooling solutions engineered for long production runs and millions of cycles.
We provide machined thin-gauge tools, cast aluminum heavy-gauge tools, 5-axis router fixtures, and check fixtures.
- Machined thin-gauge tools
- Cast aluminum heavy-gauge tools
- 5-axis router fixtures
- Check fixtures and assembly jigs
Production
State-of-the-art manufacturing facility in Greenville, SC with nearly 25,000 sq. ft. of production space.
We operate 3 heavy-gauge rotary thermoformers (forming areas up to 60″ × 100″) and 3 thin-gauge inline thermoforming lines.
- HDPE, HMWPE, ABS, HIPS materials
- PET, PETG, Polycarbonate, PVC, LDPE
- Climate-controlled clean room
- JIT delivery capabilities
Quality & Compliance
ISO 9001:2015 certified quality management system ensuring every part meets exact specifications.
Certified by Amtivo, an ANAB-accredited certification body. Every part undergoes rigorous inspection.
3D Printing
For even faster iteration, we partner with trusted local and national 3D printing specialists to deliver high-accuracy printed models and functional prototypes.
Ready to Start Your Project?
From concept to delivered parts — let's build something great together.