Custom Thermoformed PVC Clamshell for the Outdoor Sports Industry

PVC Clamshell for the Outdoor Sports IndustryA manufacturer of electronics needed a low cost solution for the packaging of one of their product lines. As the photo here shows, they needed a thermoformed end cap that would suspend their product inside of the package. It would have to be durable enough to protect the item from damage during shipping and handling, but inexpensive enough to not drive up the cost of the product.

The product that we engineered features patented shock absorbing bumpers that are specially designed to prevent damage from rough handling. The finished product not only met all of the customer’s requirements for packaging, but also reduced their cost because of our innovative use of materials.

At Plastiform, we integrate value into every product that we engineer and manufacture. This packaging solution was composed of a black medium density polyethylene (MDPE) that is formulated from postconsumer recycled materials. It was manufactured on an in-line thermoformer, with a smooth finish and dimensions of 8″ by 5″, to tolerances of ±.010″. A prototype was produced and approved before the production run of 8,000 units. Quality was maintained through fit and destructive testing to verify dimensions and wall thickness. This product highlights our ability to combine innovative features into an existing product.

Use the table below to learn more about our custom electronics packaging or contact us directly.

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Highlights of this Custom Thermoformed Project

Product Name

Sneaky Feed Gen 1 Clamshell

Product Description

Single product clamshell

Product Design & Thermoforming Project Requirements

The package had to meet specific requirements for assembly, have room for the product and documentation, while still being able to showcase the product inside.

Engineering & Thermoforming Capabilities Applied/Processes

Product Design/Development

Equipment Used to Manufacture Part

Single Station Thermo-Former

Overall Part Dimensions

Length: 15.25″
Width: 8.00″

Tightest Tolerances

± 0.002″

Material Used

Thickness: 0.020″

Material Finish


Special Features

Base has snap features to retain component during fulfillment


Maximize card size and retain wire harness

In process testing/inspection performed

Fit Testing of Product
Destructive Testing
Cutting the Part and Measuring Material Thickness

Industry for Use

Outdoor Sports



Delivery/Turnaround Time

6 Weeks

Standards Met

Customer Design Requirements

Delivery Location

Dallas, Texas