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Precision Vacuum Forming

Thermoforming is the oldest and most common method of forming heated materials into three-dimensional shapes, dating back to ancient Micronesia and Egypt.

Vacuum forming is the most common method of thermoforming, whereby flat plastic sheets are heated to a pliable temperature and drawn over or into a mold by a vacuum until it takes on the desired shape and cooled.

Vacuum formed products are all around us and play a major part in our daily lives, from simple blister packaging to the detailed interiors of automobiles, trains, ships and aircraft. This popularity is due to the fact that vacuum forming is the most economical method of producing these products. Quick start up, low tooling costs, effective prototyping and material diversity are just some of the reasons why vacuum forming is the preferred method of forming plastics, from home hobbyists to industrial manufacturers.

A common misconception is that vacuum forming is not geared towards precision products due to the fact that the plastic is formed over or into a one-sided mold. This is not true. Undercut structured female molds, a stable production process, exact calculation of the material shrinkage, CNC milling and associated after-processes have turned vacuum forming into a technically precise industry. 

Plastic Systems is comprised of a team of over 50 talented individuals with many years of experience in the custom vacuum forming industry. Our success and reputation for quality is primarily attributed to our dedicated employees, their quality workmanship and dynamic solutions.

Vacuum Forming ISO 9001:2008
Vacuum forming company

Plastic Systems is an DIN EN ISO 9001:2008 quality management certified company, established in 1993 and provides a complete manufacturing process from concept to finished product. Our central European production facility, of over 5000 sq. meters, is nestled in the scenic Sumava National Forest of the Czech Republic and located within a one day transit to over 70% of the European population.

We recognize the importance of our customer's production deadlines and operate within a strict manufacturing plan to meet the schedules agreed upon at the ordering stage. Our plant operates 24 hours a day, allowing us the flexibility to quickly adjust for rushed or altered orders and provide you with the added assurance that any urgent backup or assistance, which may be required of us, can be provided.

Our goal is to deliver your product in a consistent, timely, and cost efficient manner. To accomplish this, we turn to the expertise of our team to outline the specific production stages necessary to complete your project. Your particular product may include designers, programmers, mold makers, thermoformers, millers, assemblers, quality control personnel and more. The thermoplastic sheets and related hardware or supplies for your product must also be chosen, calculated and procured in a timely manner.

To coordinate this process and scheduling, a project manager is assigned to each product. Your product manager is the person who understands your requirements, has an overview of the complete process and is ultimately accountable for deadlines and final product quality. He or she is the person with whom you can speak, at any time, concerning any aspect of your project and is responsible to assure that all information is passed on to the relevant members our team.

At Plastic Systems, we believe that initial planning and careful review is the key to streamlining the production process, keeping the costs low and forestalling any problems.

Below is a brief explanation of our capabilities and production stages common to most products:


A proper, detailed drawing of your product is a necessary and time-saving stage for each project. From these drawings, our CAD engineers develop 3D models and the computer programs written to produce prototypes, molds and/or mill the final product. More importantly perhaps, drawings detail the specifications and tolerances which are necessary for us ensure the quality of your product throughout the process.


For first-run products and any number of other reasons, a 3D computer model may not be sufficient and the customer may choose to first produce a prototype of their product. Although many of the processes remain the same, vacuum-forming molds can be produced from a number of inexpensive and temporary materials at a much lower cost.


The mold making process, relatively speaking, is an expensive stage of the project; especially for smaller orders. We construct positive and negative vacuum forming molds, with or without internal cooling, from a number of materials ranging from steel or aluminum to wood and plaster. Choosing the proper mold construction and material to match your product is crucial to keeping costs low.

Material Management

The thermoplastic in most products accounts for between 30% to 50% of the final product cost. Determining the type, size, thickness, purity and manufacturer of the material is very important. We help you choose the proper material at the best price and arrange for material forecasting, scheduling, procurement, quality control and warehousing.

Vacuum Forming

The vacuum forming process is fairly straightforward but streamlining that process to produce a consistent quality with optimal time settings is a learned skill. Our thermoformers draw on years of experience and data to achieve the optimum process for your product.

CNC Milling

Many of the products that we produce require the removal of the thermoformed trim or a contour milled to specific dimensions. We employ a number of 3,4 and 5 axis computer operated CNC milling machines for the purpose of shaping your product to within 1/10th of a millimeter precision on a consistent basis. We also operate a CNC lathe for production of any inserts or domes which may be a part of the final product.

Related Processes

Plastic Systems offers a full range of in-house services to complete the project from beginning to end. Your product may require any one of a number of additional processes such as gluing, painting, printing and/or assembly. We can also procure special packaging and arrange for direct distribution to your customers if necessary.

Quality Control

We've listed quality control in the last position and it is indeed the final stage of any process for all products. The fact is, that quality control is an integral part of each process from the beginning and throughout the project. Our quality control includes production supervisors and machine operators who are constantly monitoring and inspecting our work at every stage to maintain the consistent quality agreed upon with our customers.

We look forward to building a relationship with you and your company.


Plastic Systems.s.r.o.
Pražská 250
342 01 Sušice
Czech Republic
+420 376 524 482
+420 376 522 341
Plastic Systems email


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