Thermoforming
Plastic Wall Caddy (Armrest)
Thermoforming
Vinyl Laminated Wall Caddy (Armrest)
Thermoforming Plastic Formed Headliner
Thermoforming
Plastic Formed Overhead Valance (Can be Vinyl Laminated as well)

Salient Designs, a division of SportChassis LLC, has provided high quality thermoforming services for the automotive, truck, HVAC, aerospace, marine and residential industries since its founding in 1999. We specialize in manufacturing specialized interior and exterior thermoformed products to exact specficiations.

Thermoforming is used to manufacture large plastic parts. With a shorter lead time and more flexible tooling designs than injection molding, thermoforming is a cost-effective method to manufacture precision parts. Thermoforming offers close tolerances, tight specifications, and sharp details. The process involves heating a flat sheet of thermoplastic material until it softens and is stretchable.  The hot sheet is then stretched over and forced against the contours of the mold by removing air from the area between the mold and the sheet, typically by vacuum process.  After cooling, the plastic sheet retains the mold shape and detail.  The formed part is then trimmed from the sheet. 

Our expert staff works with each customer to design and manufacture each product to exact specifications and application requirements.  Our efficient processes ensure low-cost, high quality products with a fast production turnaround. Salient Designs’ turnkey thermoforming capabilities include:

Design Freedom – Our thermoforming processes offers design flexibility that is not available from other manufacturers. Salient’s experienced design and thermoforming staff will work with you to design and manufacture a part that meets your exact requirements and will meet or exceed your performance expectations.

Inhouse tooling – We will design and manufacture the tooling for your project inhouse, ensuring high quality and fast turnaround.

Thermoforming – At Salient Designs, our processes ensure that your finished products meet the most exacting requirements. 

  • Fully equipped production facility includes automated and hand-forming machinery and 3-axis CNC equipment, with 5-axis availabliltiy offsite
  • Thin and thick gauge thermoforming
  • Sheet sizes up to 4’W  x 12’L, with thicknesses from 30/1000” to 300/1000”
  • Wide range of materials, including PVC, ABS,PETG, TPO, polystyrene, polyethylene and polypropylene
  • Quantities from prototype up to product runs of 3-4,000

Vinyl Lamination –Salient Designs offers custom vinyl lamination services to provide texturing, cushioning and surface protection for your thermoformed part.

Salient Designs has earned the reputation for manufacturing high quality thermoformed products for specialized applications, quickly and economically.  Let us assist you in making your product designs a reality.

Prototyping
Boat Dash after changes made. Prototype first shot sample with changes prior to approval.

Salient Designs, a division of SportChassis LLC, provides prototyping services for custom thermoformed parts. We manufacture specialty parts for the automotive, truck, HVAC, aerospace, marine and residential industries. 

Our prototyping services are used to:

  • Test the functionality of new designs
  • Test whether products meet requirements prior to full production.

Working with your design, we can develop a sample pattern and tooling to manufacture prototypes. Use of sample patterns and tooling speeds turnaround and saves costs by allowing easy, fast adjustments to the molds after testing. Once the part design has been validated, permanent tooling can be manufactured and the part put into full production.

With over 60 years of combined engineering and design experience, Salient Designs’ staff has the industry expertise to understand your application and work with you to design and test prototypes for you. We can help make your idea become a reality and manufacture a product that meets your high quality standards, efficiently and cost-effectively.

 

Design Services

This rear bumper cover was presented to us in 6 pieces, we re-engineered it and now it is a 1 piece cover.

We provide a custom turnkey thermoforming services, including design and engineering services.  Our expertise is manufacturing specialty products such as mobile video, consoles, holders and panels for the automotive, truck, marine, aerospace, HVAC and residential industries. With over 60 years of combined experience, our engineering staff has the industry expertise to understand your application and work with you to design a unique product for you.

They will manage your project throughout the design, prototype, production and quality control processes. We can take your product idea, whether is just an idea, a sketch on a napkin or a detailed CAD file, and:

  • Determine if thermoforming is the most effective manufacturing process.  If it is not, we can recommend the best manufacturing process for you.
  • Review your requirements so that we fully understand your project and the finished part will meet your expectations. We will prepare pricing estimates, delivery schedules and project designs.
  • Design tooling for in-house development and manufacturing, and produce prototypes for evaluation.
  • Determine the most effective manufacturing method and materials for your project
  • Manufacture the part to meet your exact specifications and to the highest quality standards

Salient Designs can help make your idea become a reality and manufacture a product that meets your high quality standards, efficiently and cost-effectively.

Prototyping
Boat Dash after changes made. Prototype first shot sample with changes prior to approval.

Salient Designs, a division of SportChassis LLC, provides prototyping services for custom thermoformed parts. We manufacture specialty parts for the automotive, truck, HVAC, aerospace, marine and residential industries. 

Our prototyping services are used to:

  • Test the functionality of new designs
  • Test whether products meet requirements prior to full production.

Working with your design, we can develop a sample pattern and tooling to manufacture prototypes. Use of sample patterns and tooling speeds turnaround and saves costs by allowing easy, fast adjustments to the molds after testing. Once the part design has been validated, permanent tooling can be manufactured and the part put into full production.

With over 60 years of combined engineering and design experience, Salient Designs’ staff has the industry expertise to understand your application and work with you to design and test prototypes for you. We can help make your idea become a reality and manufacture a product that meets your high quality standards, efficiently and cost-effectively.


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