Properties, pros/cons, and selection criteria for ABS, PETG, PC, HIPS, TPO, rABS, and other common thermoforming sheet grades.
BRT USA Engineering Team · Materials & Process
Published July 9, 2026
Material selection drives cost, cosmetics, regulatory compliance, and field performance. This thermoforming materials guide summarizes the grades Blue Ridge Thermoforming runs daily in thin gauge packaging and heavy gauge structural applications — and when to choose each.
Higher stiffness and heat vs PETG; opaque; excellent for paint and texture; common 0.125"–0.375" sheet for housings and dunnage.
Clear or colored transparency; strong forming window; FDA-friendly grades for medical/device packaging; typical 0.020"–0.060" sheet.
Recycled content thermoforming is increasingly specified in automotive and consumer programs. Post-industrial rABS and rPET can meet mechanical targets when sourced and validated correctly. Bio-content and mass-balance grades are emerging options when customer sustainability targets require them — validate forming behavior before tooling. Specify required test data (impact, tensile, color) early — not all recycled streams are interchangeable.
Our team recommends grades based on environment, cosmetics, regulatory needs, and volume — before you commit to tooling.
There is no single best plastic — it depends on application. ABS and HDPE dominate heavy gauge structural parts; PETG and HIPS are common in thin gauge packaging. Share your environment, cosmetic, and regulatory requirements for a specific recommendation.
Yes. Post-industrial rABS and rPET are widely used when material is qualified for impact, color, and consistency. Customer programs should define acceptable recycled content and test protocols.
ABS is preferred for opaque structural housings and heavy gauge parts. PETG is preferred for clear or thin packaging, medical trays, and applications needing sealability and chemical resistance.