What makes a part 'large'
Large-part thermoforming generally means a component over 6 feet in at least one dimension. At that size, the part needs a machine envelope, oven capacity, and material handling most contract thermoformers don't have.
The equipment that makes it possible
Floe Thermoforming's 3-station rotary thermoformer forms a 10×24 ft window, 6 ft of draw, and .600" gauge, the largest rotary thermoforming machine in the world. That envelope keeps a big part a single piece instead of a multi-piece assembly.
When to choose it
Choose large-part thermoforming when the part is oversized, the volume runs in the hundreds-to-thousands annually, and you want to replace fiberglass or a multi-piece metal assembly with one repeatable part.