Thermoform Prototyping & Tooling - Batavia, Illinois - Tek Pak, Inc
Tek Pak, Inc. | Advancing the Science of Thermoforming

Thermoform Production Tooling &Prototyping services by Tek Pak, Inc.

Thermoform Prototyping & Tooling

Thermoform Prototyping & Tooling

With over 20 years’ experience in providing high quality thermoform solutions, we are proud to offer diverse services at Tek Pak, Inc. including production thermoform tooling services for your high-volume projects.   Tek Pak builds production tooling for all types of thermoforming machines (Brown, Sencorp, Lyle, Kiefel and many others) to run in your facility.  We use state-of-the-art equipment to take your thermoform part from a concept to reality in record time. Our expert designers and toolmakers have over 100 years of collective experience in producing thermoform prototypes and tooling for the electronics, medical, food and consumer industries.  Our tool room has the most CNC machining centers in the thermoforming industry, which enables us to produce tooling for prototypes quickly and shortens our lead times for production tooling.  Tek Pak builds all types of tooling components:  jigs, fixtures, sealing tools and stacker assemblies.  Tek Pak tests all of the prototype tools that we produce in roll-fed thermoforming machines using pressure, vacuum and plug- assist forming to simulate a production environment and generate production quality parts.  Tek Pak uses aluminum for most prototype molds to realize the highest quality prototypes and to enable the tooling to produce thousands of parts.  The production tools we build are not limited in size as our largest CNC machining center can accommodate work pieces of up to 60” long, 40” wide and 15” deep. Our work is highly precise, allowing us to reach tolerances of ± 0.0005” in some cases. Our ISO 9001 and ISO 13485 certifications guarantee high quality and efficient work, and at Tek Pak we are well known for fast turnaround times. We offer 1-week prototype service, and 3-week service for production tool stacks (some conditions apply).

To learn more about our thermoform prototyping and tooling, please see the following table, click on the link below to our online catalog or contact us directly.

Thermoform Prototyping & Tooling Capabilities

General Capabilities
  • Analysis
  • Assembly
  • Contract Manufacturing
  • Consulting
  • Design (CAD)
  • Fabrication
  • Polymer Testing
  • Research & Development
  • Repair
  • Trim Tooling
  • Rapid Prototyping
  • Tooling
  • Packaging
  • Tray Design
  • Turn-key
Machining Capabilities
  • CNC Machining Centers (11)
  • Surface Grinding
  • Wire EDM
  • Lathes
  • Bridgeport Mills
Mold Tooling Material
  • Aluminum only (no plastic, wood, epoxy, etc.)
Plug Assist Materials
  • Syntactic Foam (B1X, WFT, W, FLX)
  • REN
Tooling Categories
  • Prototype Molds
  • Production Mold Tooling
  • Steel Rule Dies
  • High-Speed Cavity Machining
  • Matched-Metal Punch/Die Sets
Machinable Dimensions
  • Length: 60”
  • Width: 40”
  • Height: 30”
General Machining Tolerance (+/-)
  • ±0.005”
Thermoforming Materials
  • ABS
  • APET
  • RPET
  • PETG
  • HIPS
  • PP
  • HDPE
  • PBT
  • PC
  • PVC
  • PVDF
  • PEI
  • PPE
  • PPO
  • TPU
Thermoforming Equipment
  • Sheet-Fed Vacuum Formers (2)
  • Roll-Fed Vacuum Former (1)
  • Roll-Fed Thermoformers (3)
    • Pressure
    • Vacuum
    • Plug assist
  • Tek Pak-Built Mini Thermoformers for Precision Forming
    • Radiant Heat
    • Contact Heat
Additional Services Provided
  • Mold Design
  • Mold Repair and Welding
  • Reverse Engineering
Secondary Services
  • Forming
  • Punching
  • Engraving
  • Surface Grinding
  • Surface Finishing
Production Volume
  • Specialty Production Shop
  • Prototype
  • Low Volume
  • Medium Volume
  • High Volume
Typical Lead Time
  • 1 to 2 weeks (Prototype tooling and sampling)
  • 4 to 6 weeks (Production tooling)
  • Rush Services
  • Emergency Services

Additional Information

Industry Focus
  • Medical
  • Healthcare
  • Electronic
  • Semiconductor
  • Consumer
  • Packaging/Shipping
Industry Standards
  • ISO 9001:2008
  • ISO 13485:2003
Preferred File Formats (we can convert just about any file type for use, but we work natively with the following):
  • AutoCAD (DWG,DWZ)
  • MasterCam (MDX, MC8, MC9, SET)
  • Pro-E or Pro/Engineer (DRW,PRT,XPR)

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