Thermoforming Design
& Pattern Making
Expert thermoforming pattern design in SolidWorks. From concept to production-ready tooling drawings — designed by a specialist with 30 years in plastics manufacturing and 15 years of dedicated thermoforming experience.
The Specialist Service
What is Thermoforming
Pattern Design?
Thermoforming pattern design is the process of creating the 3D CAD model of the mould (or "pattern") over which a heated plastic sheet is formed. The quality of the pattern design directly determines the quality, consistency, and cost of every thermoformed part produced from it.
Unlike injection moulding, thermoforming patterns are typically machined from aluminium, resin, or wood — making the design phase critical. A poorly designed pattern results in parts that stick, distort, or have inconsistent wall thickness. A well-designed pattern produces clean, repeatable parts with minimal scrap.
At Birkett CAD Services, thermoforming pattern design is not a secondary service — it is a core specialism. With 15 years of dedicated thermoforming experience (and 30 years in plastics manufacturing overall), every pattern is designed with the forming process, the toolmaker, and the production line firmly in mind.
Precision thermoforming pattern design — every pocket, wall, and radius engineered for reliable forming
The Birkett Advantage
Why Choose a Specialist
Thermoforming Designer?
15 Years in Thermoforming
Chris Birkett began his career as an apprentice toolmaker and has spent 15 years working in plastics manufacturing — including injection moulding and thermoforming. This is not theoretical knowledge; it is hard-won, shop-floor experience.
Designs That Form Correctly
Most CAD designers have never stood next to a thermoforming machine. Every pattern design from Birkett CAD Services is reviewed for draft angles, wall thickness, draw ratio, and undercut avoidance — before a single line of tooling code is written.
Production-Ready Drawings
You receive fully dimensioned technical drawings for the pattern, ready to hand directly to your toolmaker. No back-and-forth, no ambiguity — just clear, manufacturable documentation that saves time and money.
SolidWorks Premium
All thermoforming pattern designs are produced in SolidWorks Premium — the industry standard for plastics tooling design. Files are delivered in native SolidWorks format plus STEP/IGES for compatibility with any toolmaker.
Faster Than a Large Agency
As an independent specialist, projects move quickly. There is no project manager queue, no account handler, no delay. You work directly with the designer from brief to delivery.
Bridge to Your Thermoformer
Birkett CAD Services acts as the technical bridge between your product idea and your thermoforming manufacturer. We can liaise directly with your toolmaker to ensure the design is optimised for their specific machinery and process.
How It Works
The Thermoforming Design Process
From your initial brief to a complete, production-ready thermoforming pattern design package — here is exactly how we work.
Concept & Brief
We start with your product requirements — dimensions, the components to be housed, material preferences, and production volumes. A clear brief means fewer revisions and faster turnaround.
3D Pattern Design in SolidWorks
The thermoforming pattern (mould) is designed in SolidWorks Premium. Every pocket, wall, draft angle, and radius is engineered for correct forming behaviour and reliable demoulding.
Design for Manufacture Review
With 15 years of thermoforming experience, every design is reviewed for draft angles (typically 3–5°), minimum wall thickness, undercut avoidance, and sheet draw ratio before any tooling is cut.
Technical Drawings for Toolmaking
Full dimensioned technical drawings are produced for the pattern/mould, ready to hand directly to your toolmaker or CNC machinist. No ambiguity — just clear, manufacturable data.
Prototype & Iterate
3D printed prototypes of the pattern can be produced for fit and function checking before committing to aluminium or resin tooling — saving significant cost on first-off tools.
Production-Ready Package
You receive a complete design package: SolidWorks files, STEP/IGES exports, technical drawings, and a bill of materials — everything your thermoformer needs to go straight into production.
Examples
Types of Thermoformed Products We Design
From simple single-pocket trays to complex multi-compartment packaging — every thermoforming pattern design is engineered for reliable production.
Industrial Component Trays
Multi-compartment black ABS trays for component storage and transit — designed with precise pocket geometry and draft angles for reliable demoulding.
Multi-Compartment Packaging Trays
Custom thermoformed packaging trays with varied pocket sizes — ideal for retail packaging, kitting, and product presentation.
Food & Retail Packaging
Clear PETG and PET thermoformed trays for food and retail applications — designed to food-safe standards with optimised wall thickness.
Medical Device Trays
Precision thermoformed trays for medical devices and instruments — designed to exacting tolerances for secure component retention.
Transit & Shipping Trays
Stackable thermoformed transit trays designed for automated handling lines — with locating features and stacking geometry built in from the CAD stage.
Electronics & ESD Trays
Anti-static and conductive thermoformed trays for electronics components — designed to protect sensitive devices throughout the supply chain.
Engineering Knowledge
Critical Thermoforming Design Considerations
These are the engineering details that separate a thermoforming pattern that works first time from one that causes expensive problems on the forming machine.
Draft Angles
Minimum 3° draft on all vertical walls — typically 5° for textured surfaces. Insufficient draft causes the formed part to stick to the pattern, leading to distortion and scrap.
Wall Thickness
Thermoforming thins the sheet as it stretches. Deep draws require careful geometry to maintain adequate wall thickness at the base and corners — this is designed in from day one.
Undercuts
Undercuts prevent part release and must be avoided or addressed with split-tool designs. Every thermoforming pattern design is checked for undercuts before tooling commences.
Corner Radii
Sharp internal corners cause stress concentrations and thinning. All internal radii are designed to a minimum of 1.5× the sheet thickness to ensure consistent wall thickness.
Draw Ratio
The draw ratio (depth vs. width) determines how much the sheet stretches. Deep-draw designs require careful material selection and geometry to prevent excessive thinning.
Nesting & Stacking
For transit and storage trays, nesting geometry is designed in from the start — ensuring trays stack efficiently without jamming, saving warehouse space and handling time.
Material Expertise
Thermoforming Materials We Design For
Material selection directly affects pattern design — wall thickness, draft angles, and draw ratio all vary by material. We design for the material, not around it.
High Impact Polystyrene
General purpose trays, packaging, POS displays
Acrylonitrile Butadiene Styrene
Industrial trays, automotive components, housings
Polyethylene Terephthalate Glycol
Clear packaging, food-safe trays, medical
Polyethylene Terephthalate
Food packaging, blister packs, retail trays
Polypropylene
Chemical-resistant trays, living hinges, reusable packaging
Polycarbonate
High-clarity covers, machine guards, optical applications
High-Density Polyethylene
Heavy-duty transit trays, chemical containers
Conductive / Anti-Static
Electronics component trays, PCB handling, semiconductor packaging
Sectors Served
Industries We Design Thermoforming For
Food & Beverage Packaging
Retail food trays, portion packs, produce packaging
Medical & Healthcare
Instrument trays, device packaging, sterile barrier systems
Automotive
Component trays, assembly line carriers, transit packaging
Electronics
ESD trays, PCB carriers, component handling trays
Industrial & Logistics
Transit trays, racking inserts, kitting trays
Retail & Point of Sale
Display trays, blister packs, product presentation
Making the Right Choice
Thermoforming vs Injection Moulding: When to Choose Which
| Factor | Thermoforming | Injection Moulding |
|---|---|---|
| Tooling Cost | Low–Medium (£500–£5,000) | High (£5,000–£50,000+) |
| Lead Time to First Part | Days to weeks | Weeks to months |
| Part Size | Excellent for large, shallow parts | Better for small, complex parts |
| Wall Thickness | Variable (thinner at draw) | Highly consistent |
| Production Volume | Low–Medium (100–50,000) | Medium–High (10,000+) |
| Design Changes | Low cost to modify pattern | Expensive to modify steel tool |
| Undercuts | Difficult — avoid in design | Achievable with side actions |
| Ideal For | Trays, covers, packaging, housings | Complex geometry, tight tolerances |
Not sure which process is right for your product? With 30 years in plastics manufacturing — including 15 years of dedicated thermoforming experience — Birkett CAD Services can advise on the most cost-effective route for your specific application — before you commit to tooling.
Common Questions
Thermoforming Design FAQ
Ready to Start Your
Thermoforming Design?
Get in touch for a free, no-obligation discussion about your thermoforming pattern design requirements. Whether you have a sketch on a napkin or a full specification, we can help turn it into a production-ready design.
Based in Hull, East Yorkshire — serving clients across the UK