Main Services
Value-Added Services
Pattern Development (3D Digitization)
Mold Creation (CNC Machine Creates Master/Pattern)
Painting (Primer/Top)
Secondary Component Installation (PVC, Metal, Wood, and Rubber)
Our Vacuum Forming Process
At BLG, our vacuum forming plastic process is designed to produce high-quality, durable components for a variety of industries. We work with materials such as PC, ABS, PVC, PS, PET, and more, using advanced blister forming machines. The process involves heating the plastic sheet, forming it to match the mold under vacuum, cooling, and precisely trimming it on a punching machine.
Our team also performs additional finishing steps, including folding, punching, and assembly, to deliver fully functional components. Businesses across North America trust us as a leading plastic supplier for custom plastic forming in Canada, the USA, and the EU, and as a provider of composite material for commercial vehicles that meets strict industry standards.
Experienced Pros
The experts at BLG Fiberglass have the experience, knowledge and skills to design and construct the materials you need.
Reliable Results
We always deliver incredible results. This is part of our efforts to provide our clients with materials that satisfy their needs.
We Serve Many Industries
We manufacture components for many industries, including automotive, marine, wind turbines, and medical.
Value-Added Services
Pattern development, mold creation, painting, secondary component installation, and boding services.
Plastic Supplier: Benefits & Uses Explained
As a trusted plastic supplier in North America and Europe, BLG Fiberglass produces high-quality components for a wide range of applications. We specialize in custom plastic forming in Canada, the USA, and Europe, delivering durable solutions for commercial and industrial vehicles.
Our expertise includes creating components such as truck external parts, bumpers, internal panels, buses, tractors and trucks’ fenders, exterior trims, A-pillars, air deflectors, fan shrouds, windshield wiper housings (rain trays), battery boxes/covers, instrument panels, CT bodies, robot shells, and aircraft table boards using advanced vacuum forming plastics techniques.
Our composite materials for commercial vehicles Canada, the USA, and the EU are engineered for performance and longevity, offering benefits such as:
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Excellent corrosion resistance; materials will not age
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Lightweight yet strong structure
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Low operational noise
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High structural integrity with no deformation
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Superior insulation performance
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Beautiful, durable appearance with special surface treatment
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Paint with strong adhesion that resists fading
By choosing BLG Fiberglass as your plastic supplier, you can trust that every component is manufactured to meet exact specifications while delivering reliability and high-quality results for commercial vehicles and other industries.
Step-by-Step Vacuum Forming Process
Here’s what the process looks like from start to finish
Step 1: Heating the Plastic Sheet
The process begins with a flat thermoplastic sheet, typically made from materials such as ABS, PC, PVC, PS, or PET. The sheet is clamped into place and gradually heated until it reaches its forming temperature. At this point, the material becomes soft and pliable but does not melt.
Controlling the heating stage is critical – uneven heating can cause warping or weak spots in the final part.
Step 2: Applying the Vacuum
Once the sheet is properly heated, it is lowered over a pre-made mold. A vacuum pump is then used to remove the air between the sheet and the mold, pulling the softened material tightly against every contour.
This ensures accurate replication of the mold’s details.
The precision of this step directly impacts the quality, strength, and dimensional accuracy of the final component.
Step 3: Cooling & Trimming
After forming, the plastic must cool and harden to maintain its new shape.
Cooling is controlled to prevent shrinkage or deformation.
Once the part has cooled, it is carefully trimmed using CNC cutting or punching machines to remove excess material and achieve the final dimensions.
This trimming stage is where tolerances are refined to meet exact specifications.
Step 4: Finishing & Assembly
Depending on the application, additional finishing steps are performed to prepare the component for use.
This may include:
- Folding or bending for structural strength
- Drilling or punching holes for fasteners
- Painting or coating for durability and appearance
- Bonding or assembly with secondary parts
Step 5: Quality Inspection & Delivery
Before components leave our facility, they undergo strict quality control checks. Dimensions, surface finish, and overall durability are verified against customer requirements and industry standards.
Only parts that meet specifications move forward for packaging and delivery.
This final step ensures customers receive reliable, high-performance components they can integrate with confidence.
Vacuum Forming vs. Injection Molding – What’s the Difference?
| Feature | Vacuum Forming | Injection Molding |
|---|---|---|
| Tooling Cost | Lower upfront cost (affordable molds) | High tooling cost (expensive steel/aluminum molds) |
| Lead Time | Faster setup, ideal for prototypes and small runs | Longer setup, best for large production volumes |
| Part Detail | Moderate detail, good for large/simple parts | High precision, complex geometries possible |
| Production Volume | Best for low-to-medium quantities | Cost-effective at very high volumes |
| Material Use | Uses plastic sheets (less material waste) | Uses pellets, more control over material properties |
| Applications | Panels, covers, housings, trays | High-volume consumer goods, automotive parts |
Vacuum Forming vs. Thermoforming – What’s the Difference?
| Feature | Vacuum Forming | Thermoforming |
|---|---|---|
| Definition | Uses vacuum pressure to pull heated plastic sheet over a mold. | General process of heating plastic sheets and shaping them with molds (includes vacuum forming). |
| Process Specificity | Subset of thermoforming focused on vacuum suction. | Umbrella term for several methods: vacuum forming, pressure forming, twin-sheet forming. |
| Detail Level | Moderate detail; good for simple or large parts. | Can achieve higher detail with pressure forming or twin-sheet methods. |
| Cost | Lower tooling cost, best for prototypes and short runs. | Cost varies—some methods more expensive, but more versatile. |
| Applications | Trays, enclosures, housings, packaging. | Packaging, medical trays, automotive panels, consumer products. |
INDUSTRIES WE SERVE
We have been working with a number of different clients from a variety of industries. People come to us because we always deliver amazing final results that our clients love. If you need customized solutions for your components, our fiberglass and compound manufacturing company is the one you will want to call. Our team manufactures components for businesses in many industries including:
Vacuum Forming FAQs
Have questions about our vacuum forming process, materials, or applications?
Here are the answers to the ones we hear most often.
Which materials do you vacuum form, and which should I choose for my part?
The materials we vacuum from are mainly ABS, PC, PET, PS, PVC and specialty blends. Choose by requirement: ABS for good toughness and paintability; PC for impact resistance and clarity; PET for food-contact trays and stability; PS for low-cost rigid parts; PVC where chemical resistance is needed. If you tell us required strength, temperature range, and finish, we’ll recommend the optimal resin.
What wall thicknesses and tolerances can you achieve?
Typical finished wall thicknesses are 0.8-4.0 mm depending on initial sheet gauge and draw depth. Dimensional tolerances after trimming are typically ±0.5-1.5 mm for most features; tighter tolerances (±0.1–±0.3 mm) are achievable on short runs with CNC trimming and inspection – specify critical dimensions up front.
What’s the largest part size you can form?
We can form sheets up to roughly 3.0m X 2.0m.
How do design features like undercuts, deep draws, and thin ribs affect feasibility?
Vacuum forming dislikes undercuts and very deep draws. Draft angles (see next Q) and rounded transitions are essential. Deep draws may thin walls and need pressure forming or two-piece molds. If your design has undercuts, we’ll propose modification, reliefs, or a secondary assembly strategy.
What draft angles and radii should I design for?
Minimum recommended draft is 3°-5° on vertical walls. Internal radii should be at least 1-2× the final wall thickness to avoid thin spots and tearing. Sharp internal corners = weak/different wall thickness – avoid them.
How should I specify holes, inserts and fasteners?
Prefer locating bosses and inserts to be added post-forming. We can pre-punch or CNC-route holes; for threaded inserts we recommend heat-set or ultrasonic insertion after forming. Provide hole sizes and tolerance class early-we’ll advise on reinforcement or bushings if load-bearing.
What surface finishes and textures can you supply?
Smooth, satin, pebble, leather grain and custom textures are available via textured molds or post coatings. We also offer paint finishes-automotive-grade primers and topcoats with controlled adhesion processes for long life. Learn how enclosures benefit from surface choices.
Do painted finishes adhere well to all materials?
Not automatically. ABS and PC accept paint well with proper surface prep (flame or plasma treatment, primer). PVC and some proprietary blends may need specific primers. We test adhesion and provide adhesion certifications on request.
Can you match colors / Pantone values?
Yes. For sheet color we match to RAL or Pantone with a small color tolerance. For painted finishes we can do closer Pantone matches – provide a physical swatch for best results.
What secondary operations do you provide?
CNC trimming, punching, folding, heat-bending, drilling, painting, bonding, assembly, insert installation and custom packaging. We can deliver ready-to-install assemblies.
How long will tooling and parts take?
Typical lead times: prototype mold & 1–3 weeks for simple parts; complex molds 3–6 weeks. Production runs: 1–4 weeks depending on quantity, finishing, and assembly. We give a detailed schedule with every quote.
What are the main cost drivers?
Part complexity and draw depth, mold material (MDF vs aluminium), sheet material and gauge, finish/painting, secondary operations, and quantity. Provide a BOM and annual volume estimate for the most accurate pricing.
Can you meet medical, food-contact or aerospace requirements?
Yes – but material and process choices must be validated. For medical/aerospace we use certified resins, controlled clean processes, and can provide material certifications (batch traceability). For food contact, we’ll supply FDA/EC compliant materials on request.
What quality control and inspection do you perform?
Visual inspection, dimensional checks (calipers/CMM on critical features), surface finish verification, adhesion tests for painted parts, and lot traceability. We can provide inspection reports and first-article inspection upon request.
What packaging and shipping options are available?
Custom foam crating, palletizing, and protective film are standard. For exports to the USA/EU we handle export packaging and documentation. Tell us if parts need ESD protection, cleanroom packaging, or kitting.
What’s your minimum order quantity (MOQ)?
For standard vacuum formed parts, MOQ depends on finish and tooling amortization: prototype runs can be as low as 1–10 parts, while production MOQ typically starts around 50–200 parts. Exact MOQ is quoted per job.
Do you sign NDAs and protect IP?
Yes – we will sign NDAs and control access to tooling and drawings. Request an NDA when sending sensitive designs.
What warranty do you provide?
We warrant parts against manufacturing defects and workmanship for a specified period (typically 12 months)-warranty terms are included in the quote and exclude damage from improper installation or abuse.
Can you do prototypes and functional samples before full production?
Yes. We recommend a prototype run to validate fit, finish and assembly – prototypes can be produced in final material or a close substitute, then revised quickly before tooling finalization.
Why choose BLG Manufacturing?
BLG is a Canadian-based company founded in 2000 with headquarters in Toronto, Ontario. Our facilities in Shanghai and Jiangsu China comprise more than 50,000 square meters of office and manufacturing space. We specialize in manufacturing high-quality fiberglass products and providing bespoke solutions to meet our customers’ needs.
As the leading fiberglass and plastic supplier in Canada and other countries, we offer shipping to North America, South America, Europe, and Asia. Our primary fiberglass services include Fiberglass Reinforced Plastic (FRP), Resin Transfer Molding (RTM), and Sheet Molding Compound (SMC) and Forming Plastic. We have the expertise to provide customized fiberglass solutions to cater to our customers’ unique requirements.
Servicing Customers Worldwide
Our Partners
Our company has developed strong working relationships with companies from so many industries because of our commitment to delivering high-quality components.
Get In Touch Today
If you are looking to get a quote on your project or you need more information about our team and services, we encourage you to get in touch with us today. We look forward to hearing from you.