We thermoform semi-rigid products engineered for complex, lightweight designs
Fulflex specializes in thermoforming semi-rigid plastic for medical applications. Thin- to medium-gauge sheet forming produces semi-rigid components that enable complex geometry with controlled wall thickness.
As a fully integrated contract manufacturing partner, we support customers from early design-for-manufacture(DFM) through tooling, process validation, and long-run production.
Build new. Replicate exact.
Our thermoforming capabilities are built for both! Reach out to us for inquiries.
Capability Pillars
Lightweight Design
Up to 50% lighter than equivalent rigid products while maintaining structural integrity.
Complex Geometry
Precision forming supports thin-wall structures and intricate part geometry.
Regulatory Compliance
Validated manufacturing under FDA QSR and ISO 13485, with full IQ/OQ/PQ documentation.
Technical Specifications
Thermoforming Equipment Capabilities
Machine / process type
Pressure / vacuum sheet thermoforming
Sheet gauge range
0.3 mm to 1.5 mm
Wall thickness control
Controlled draw ratio for consistent wall thickness
Tooling
Single to multi-cavity forming tools
Material compatibility
Polypropylene (PP), medical-grade plastics
Production environment
Dust-free
Production & Supply Parameters
Annual volume capability
Millions of units per SKU across multi-cavity tooling
Minimum order quantity
Negotiated per programme - aligned to OEM demand profile
Packaging options
Custom bulk, inner-packed
Quality standard
ISO 13485:2016 / FDA 21 CFR Part 820 (Quality System Regulation)
AQL level
Per customer specification
Traceability
Lot-level
Customer audits
Fully supported and welcomed