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From CT scanner gantry covers to ventilator housings — precision thermoformed enclosures that meet the demanding aesthetic, functional, and regulatory requirements of the medical device industry.
80%
Lower Tooling Cost
4–6 wk
First Article Lead
4250mm
Max Forming Size
6+
Medical Materials
Why Thermoforming for Medical?
Medical device enclosures require premium surface quality, tight tolerances, and regulatory compliance — all at production volumes where injection molding tooling is prohibitively expensive.
Aluminum thermoforming molds cost $5,000–$25,000 vs. $100,000–$500,000 for injection molds. Critical for medical devices with lower production volumes and frequent design iterations.
Form single-piece enclosures up to 4250×2500mm — essential for CT scanner gantry covers and MRI bore liners that cannot be economically injection molded.
Pressure forming at 3–6 bar produces surfaces indistinguishable from injection molding. Sharp radii, crisp details, and textured finishes without secondary painting.
Choose from ABS, HIPS, PC, PETG, Kydex, and specialty grades. Each material can be selected for specific requirements: chemical resistance, flame retardancy, or optical clarity.
From concept to first article in 4–6 weeks. Aluminum tooling enables design changes without the cost penalty of steel mold modifications.
Materials available with FDA, USP Class VI, and ISO 10993 biocompatibility certifications. Full material traceability and lot documentation for medical device submissions.
Medical Application Portfolio
Precision thermoformed enclosures for imaging equipment, respiratory devices, diagnostic instruments, surgical systems, and patient care equipment.
Large-format gantry covers, patient table shrouds, and bore liners for CT and MRI scanners. Pressure-formed ABS delivers Class-A surfaces with tight tolerances for equipment integration.
Equipment housings and covers for ventilators, CPAP machines, and respiratory therapy devices. Thermoformed ABS and HIPS provide impact resistance and chemical compatibility for hospital environments.
Housings for blood analyzers, ultrasound machines, X-ray equipment, and laboratory instruments. Pressure forming achieves injection-mold-quality surfaces at a fraction of the tooling cost.
Covers and housings for dental chairs, imaging systems, and sterilization equipment. Thermoformed panels withstand repeated disinfection with hospital-grade chemicals without degradation.
Exterior panels and arm covers for surgical robotic systems. Lightweight thermoformed components reduce system weight while maintaining the premium aesthetic that operating room equipment demands.
Head and foot boards, side rail covers, and under-bed equipment housings for hospital beds and stretchers. Impact-resistant ABS withstands daily use in high-traffic clinical environments.
Process Selection
The choice between pressure forming and vacuum forming depends on the surface quality, detail resolution, and tolerance requirements of each medical device component.
Recommended for exterior-facing enclosures where surface quality is critical:
Cost-effective for internal components and non-visible enclosures:
Material Selection
From impact-resistant ABS to optically clear PETG — every material is selected for the specific functional, aesthetic, and regulatory requirements of the medical device.
| Material | Medical Application | Key Properties | Thickness | Certification |
|---|---|---|---|---|
| ABS | General enclosures, covers, housings | Impact resistant, formable, cost-effective | 1.5–6mm | UL94 HB |
| ABS FR V0 | Electrical enclosures, near-patient equipment | Self-extinguishing, low smoke | 1.5–5mm | UL94 V-0 |
| HIPS | Interior panels, trays, covers | Lightweight, easy to form, low cost | 1–4mm | FDA available |
| PC (Lexan) | Transparent windows, safety shields | Optically clear, impact proof | 1.5–6mm | UL94 V-0 |
| PETG | Transparent covers, display windows | Chemical resistant, clear | 1–4mm | FDA, ISO 10993 |
| Kydex | High-wear surfaces, antimicrobial panels | Chemical resistant, fire rated | 1–3mm | FAR 25.853 |
| ABS/PMMA | Premium exterior housings | High gloss, scratch resistant, UV stable | 2–5mm | UL94 HB |
Deep Dive: Imaging Equipment
CT and MRI scanner covers are among the most demanding thermoforming applications — requiring large-format capability, Class-A surfaces, and precise dimensional control for equipment integration.
CT and MRI scanner covers are produced in volumes of 100–2,000 units per year — a sweet spot where thermoforming offers significant advantages over injection molding:
$10K–$25K
Thermoform Tooling
Aluminum molds with CNC-machined detail
$200K–$500K
Injection Mold Tooling
Steel molds required for equivalent size
4–6 weeks
Tooling Lead Time
vs. 16–24 weeks for injection molds
< $500
Design Change Cost
Modify aluminum mold vs. re-cut steel
Hygiene & Cleanability
Medical device enclosures must withstand daily cleaning with aggressive hospital-grade disinfectants while maintaining their appearance and structural integrity over years of service.
Whether you're developing a new medical device or looking to convert existing metal enclosures to thermoformed plastic, we'll provide a complete technical proposal with material recommendations, tooling costs, and production pricing.