Innovated Thermoforming Solutions 50 Years in the Making

With decades of experience forming a variety of materials up to .5” thick in sizes up to 60” x 104” x 36” deep, the Lane Company team is unparalleled in our ability to thermoform your unique project quickly, correctly, and with exemplary quality. Our top-of-the-line equipment coupled with our extensive expertise in vacuum and pressure forming allows us to be flexible, collaborative and a true partner to our clients throughout the entire thermoforming process.

One of the oldest methods of part creation, drape forming is a process in which a plastic sheet is heated to pliability so it can be pressed, bent, or formed into or over a mandrel or form. Drape forming is favored by those seeking a budget-friendly manufacturing process thanks to its low-cost tooling and fixtures.

Line bending is used to bend plastic into a straight line. The process heats a thermoplastic sheet over a strip heater until it becomes soft, then bends it into any desired angle. Lane Company’s state-of-the-art thermoforming equipment can create multiple bends in one cycle, offering more economical and efficient manufacturing.

As with any project that requires a manufacturing process, a strong concept is the first step. Thermoformed products run the gamut, ranging from aesthetic to functional pieces, and each concept presents its own unique features and challenges. Our clients often present us with an initial model, or CAD file that we fine-tune into a model, that we then use to determine which plastics processes will best match the project’s needs and goals.

Once the concept is completed, the next step is to determine which plastic material best suits the project. Each type of plastic has something unique to offer in its characteristics and qualities. Our expert engineers will evaluate the project’s needs and make recommendations for the most appropriate materials.

Next, a mold must be created for the chosen materials to form to during the manufacturing process. Molds are typically made of aluminum, as it works best for physical processing. It’s at this stage that our engineers will look for areas of potential time and cost savings on behalf of our clients, as there are many different ways to reach the same outcome: A high-quality, functional mold.

With the mold created, it’s now time for the thermoforming process to take place. The plastic material of choice is heated to the aluminum mold and formed using air pressure and/ or vacuum pressure. It is then cooled and removed from the mold to set.

Once a piece of plastic is thermoformed, there’s still some material that needs to be trimmed away. At Lane Company, we use 3- and 5-axis CNC routers to quickly cut complex and precise shapes, resulting in faster production times and more accurate, flexible cuts. We also perform secondary operations such as cutouts, through holes, and other features that require the removal of material at this stage in the process.

After the custom plastic piece has been created, Lane can also perform a variety of secondary operations and value-add services. These can include the installation of inserts and other fastening devices, and the assembly of hinges, handles, and other hardware if necessary. When a client receives their completed part from Lane Company, that part is ready to seamlessly integrate with the rest of their manufacturing process.