Conversion

Replacing Metal with Thermoformed Plastic

Yes. Heavy-gauge thermoforming replaces stamped and welded metal panels and enclosures with lighter, corrosion-immune, single-piece thermoplastic parts. Typical weight reduction runs 30-50% versus equivalent stamped or welded metal, with fewer fasteners, no paint operations, and consolidated assembly, at the 1,000-plus unit annual volumes where the tooling pays back fast.

Jon Novitt · VP Thermoforming 7 min read Updated June 2, 2026

Where metal-to-plastic wins

Hoods, side panels, roof caps, shrouds, housings, and enclosures are common targets. A multi-piece welded assembly collapses into one molded part with mounting features built in.

What it saves

Typical weight reduction is 30-50% versus stamped or welded metal. Corrosion disappears, paint operations disappear, and fastener and weld counts drop, cutting assembly labor along with mass.

The conversion path

Every conversion runs through DFM to engineer draft, radii, undercuts, and integrated features for forming. Material is matched to the duty cycle, tooling strategy is set to volume, and a first article is validated before production.

Related capability

Fiberglass & Metal Conversion

Explore the capability

FAQ

Questions OEM engineers ask

How much weight does metal-to-plastic conversion save?

Typically 30-50% versus equivalent stamped or welded metal, depending on the part and material.

Does conversion require redesigning the part?

Yes, every conversion goes through DFM to adjust draft, radii, undercuts, and integrated features for the forming process.

What volume justifies a conversion?

Floe Thermoforming is built for 1,000+ unit annual volumes, where consolidated tooling, eliminated paint, and reduced assembly labor typically deliver tooling payback within the first production year.

About the author

Jon Novitt

Jon Novitt is Vice President of Thermoforming at Floe Thermoforming, a division of FLOE International. He has spent 28 years in B2B manufacturing, including 19 years in thermoforming tooling, and leads engineering and production for heavy-gauge, large-format OEM programs in McGregor, Minnesota.

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Jon Novitt · 218-426-3563 JonN@floeintl.com