Mold Solutions
for Every Program.
Floe Thermoforming designs heavy-gauge thermoforming tooling in-house using CAD data and builds it through three paths: cast or billet aluminum for production volume, additive-manufactured tooling for bridge and prototype, and epoxy or wood-board for low-cost proof-of-concept. Every tool ships with quick-change capability to minimize changeover time.
Three tooling paths
Match tooling investment to where the program is, not every part needs production tooling on day one.
Epoxy / Wood-Board, Good
Lowest-cost proof-of-concept tooling for early validation and fit checks.
Additive, Better
3D-printed bridge and prototype tooling that can ship in 2-4 weeks.
Cast / Billet Aluminum, Best
Full production tooling, typically 8-14 weeks, for the life of the program.
Plug assists, draw tanks, and secondary tooling
Heavy-gauge, deep-draw parts need more than a mold. Engineered plug assists control material distribution into deep features; draw tanks and pressure boxes manage the forming itself.
Secondary tooling, robotic trim fixtures, inspection gauges, and assembly fixtures, is built alongside the mold so the whole program is supported, not just the forming step.
Multi-cavity tooling at scale
On a large enough machine, tooling stops being one cavity at a time. Floe Thermoforming's 10 by 24 foot rotary platen runs multi-cavity tooling on parts most thermoformers can only run single cavity, two, three, or four parts per cycle on the same shot.
It is the most direct lever on piece price we have. See multi-cavity tooling at scale for the configurations, the cavity-count decision, and the math a buyer can use.
How thermoforming tooling is built
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01
CAD & DFM
We take your CAD and engineer the tool for draft, radii, and material flow.
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02
Path selection
Aluminum, additive, or epoxy is chosen for the program's stage and volume.
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03
Build & assists
The mold is built with engineered plug assists, draw tanks, and quick-change features.
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04
First article
We form and validate the first article, then tune the tool.
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05
Production handoff
The proven tool runs on the same floor that built it.
Tooling resources
Multi-Cavity Tooling at Scale
Two to four large parts per cycle on the world's largest rotary.
Program Management
Where tooling strategy fits in the program.
Large-Part Thermoforming
The parts these tools form.
Heavy-Gauge Thermoforming
The process the tooling serves.
Prototype to Production
How tooling drives the timeline.
Questions OEM engineers ask
Do you build thermoforming tooling in-house?
Floe Thermoforming designs all tooling in-house using CAD and milling centers, then builds it through cast/billet aluminum, additive-manufactured, or epoxy/wood-board paths depending on the program stage and budget.
What is the typical lead time for a heavy-gauge thermoforming tool?
Lead times depend on path: additive-manufactured prototype tooling can ship in 2-4 weeks; cast aluminum production tooling typically takes 8-14 weeks; epoxy/wood-board proof-of-concept tooling can be ready in under 2 weeks.
What types of thermoforming molds does Floe Thermoforming use?
Cast aluminum, billet aluminum, additive-manufactured polymer, and epoxy/wood-board. The right mold type depends on program volume, lifecycle, and budget, Floe Thermoforming specifies the optimal path during DFM review.
What is good/better/best tooling strategy?
Good/better/best tooling lets an OEM match tooling investment to program stage. Good = low-cost epoxy or additive for early validation. Better = aluminum bridge tooling for low-volume launch. Best = cast/billet aluminum production tooling for full lifecycle.
Can a family tool reduce cost on a multi-part program?
Yes. Family tooling and multi-cavity strategies are common at Floe Thermoforming to minimize piece price and consolidate tooling investment. Strategy is part of every program management review.
Send us the part. We'll tell you how to build it.
Upload your drawing or describe the program. NDA-friendly. We review every RFQ ourselves, response within 1 business day.