184 Commerce Center, Greenville, SC 29615

Heavy Gauge Thermoforming

Large-format precision. Cost-effective durability.

At Blue Ridge Thermoforming, we operate three rotary thermoforming machines capable of producing both large and small parts with precision and efficiency.

  • Max part size: ~60” x 100”

  • Min sheet size: 12” x 16”

  • Max draw depth: 24”

  • Material thickness: .03” to .5”

We regularly work with HDPE, HMWPE, ABS, HIPS, PET/PETG, Polycarbonate, and PVC, though our equipment is capable of running a wide range of thermoplastics.

Industries & Applications​

Equipment Covers & Kiosks

We collaborate with clients to bring product concepts to life—cost-effectively and at scale.
Our process includes:

  • Tooling and production strategy

  • Virgin or paint-grade plastic

  • Precision trimming with 5-axis routing

Ready to explore thermoforming for your components?
→ Contact us today to review your part requirements.

OEM Components

From equipment covers to interior and exterior trim, Blue Ridge produces durable thermoformed parts for OEM use.
Common OEM applications include:

  • Shrouds, cowls, and trim panels

  • Door and instrument panels

  • Fenders, roofs, and engine covers

We offer color matching to PMS codes, textured surfaces, and tight-fit tolerances.

Automotive Packaging

We design custom trays for a variety of automotive parts—from alternators to engine blocks—ensuring safe, cost-effective transport and presentation-ready delivery to your customer’s assembly line.

→ Looking for custom packaging that protects and impresses? Let’s talk.

Material Handling Trays

When parts are tough to package, we design trays that simplify the process.
Our thermoformed trays are often used in automation, allowing robots to quickly identify and retrieve parts. Options include:

  • Nestable trays

  • Tray-integrated pallets

  • Automation-ready part orientation

Returnable Packaging Systems

Reduce waste and cut costs with custom returnable packaging.

We manufacture trays and pallets that are:

  • Nestable and stackable

  • Designed for efficient return logistics

  • Built for long-term reuse

Whether you’re looking to reduce cost per cycle or build a full returnable system, we’ve got the tools to help.

Let’s Build Something That Performs

Start a conversation with our team and see how we can bring your next product or package to life.

Get a Quote

About Us

Blue Ridge Thermoforming is a custom vacuum forming manufacturer in Greenville, SC. We specialize in thin and heavy gauge plastic packaging and covers for industries like aerospace, automotive, and medical. Quality-driven, we deliver on-time, precision-formed solutions with value-added services.

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