The most cost-effective material in thermoforming. HIPS (High Impact Polystyrene) delivers outstanding formability, excellent printability, and FDA food-contact compliance at the lowest price point. From refrigerator liners to retail packaging — HIPS is the material when volume and cost matter most.
5+
HIPS Grades Available
0.5–6mm
Sheet Thickness Range
Lowest
Material Cost
In-House
Extrusion from Pellets
Why Choose HIPS
HIPS (High Impact Polystyrene) is the most widely used material in thin-gauge thermoforming and a strong contender in heavy-gauge applications where cost is the primary driver.
HIPS is the lowest-cost engineering thermoplastic for thermoforming. When your application doesn't require the chemical resistance of ABS or the clarity of PETG, HIPS delivers excellent performance at the best price point.
HIPS has the widest processing window of any thermoforming material. It forms at lower temperatures, draws deeper, and reproduces detail more consistently than almost any alternative. This means fewer rejects and faster cycle times.
HIPS accepts offset printing, screen printing, hot stamping, and pressure-sensitive labels with excellent adhesion. No surface treatment or primers required — critical for branded packaging and retail displays.
HIPS is 100% recyclable as Polystyrene #6. All production scrap is re-ground and re-extruded in our facility. For sustainability-conscious brands, HIPS offers a clear recycling pathway.
HIPS is widely approved for food-contact applications. FDA-compliant grades are available for dairy packaging, produce trays, and food service containers — no coatings or liners needed.
HIPS FR grades achieve UL 94 V-0 with halogen-free formulations available. For electrical enclosures and HVAC applications where flame retardancy is required, FR HIPS offers compliance at a lower cost than ABS FR.
HIPS Grade Selection
We extrude all HIPS grades in-house from pellets — giving you access to specialty grades, custom colors, and co-extruded multi-layer sheets without minimum order constraints.
| Grade | Key Properties | Applications | Max Temp | Thickness |
|---|---|---|---|---|
| HIPS General Purpose | Good impact strength, excellent formability, smooth surface finish, easy to print and label | Packaging trays, point-of-purchase displays, appliance liners, protective covers | Up to 70°C | 0.5–6mm |
| HIPS High Impact | Enhanced impact resistance, improved toughness at low temperatures, matte finish | Refrigerator liners, equipment housings, industrial trays, automotive interior panels | Up to 75°C | 1–6mm |
| HIPS FR (Flame Retardant) | UL 94 V-0 rated, self-extinguishing, halogen-free options available | Electrical enclosures, HVAC components, lighting housings, appliance panels | Up to 70°C | 1.5–5mm |
| HIPS Conductive / ESD | Static-dissipative or conductive surface, protects sensitive electronics during handling | Electronics packaging trays, component carriers, semiconductor handling, cleanroom trays | Up to 70°C | 0.5–3mm |
| HIPS/PE Co-extruded | HIPS rigidity with PE moisture barrier, food-contact grades available | Food packaging, dairy containers, produce trays, cold-chain packaging | Up to 70°C | 0.5–3mm |
HIPS Applications
From refrigerator liners to electronics packaging — HIPS is the go-to material when formability, cost, and volume are the primary drivers.
HIPS is the industry-standard material for refrigerator door liners, freezer compartments, and appliance interiors. Excellent formability into deep draws with consistent wall thickness.
Blister packs, clamshells, medical trays, produce containers, and industrial packaging. HIPS dominates thin-gauge thermoforming for its speed, cost, and recyclability.
Retail displays, shelf organizers, and promotional stands. HIPS accepts printing, labeling, and hot stamping beautifully — ideal for branded retail environments.
Air handling unit panels, duct covers, and equipment guards. HIPS FR grades provide flame retardancy for HVAC applications at a fraction of the cost of engineering plastics.
Door panels, trunk liners, headliners, and interior trim for commercial vehicles. HIPS provides good surface quality at automotive-friendly price points.
Conductive and static-dissipative HIPS trays protect sensitive electronics during manufacturing, shipping, and storage. Custom cavities for component-specific handling.
Material Comparison
Both are excellent thermoforming materials from the styrene family. Here's an honest comparison to help you choose the right one.
| Property | HIPS | ABS | Advantage |
|---|---|---|---|
| Material Cost | Lowest (commodity) | Moderate | HIPS |
| Impact Resistance | Good | Excellent | ABS |
| Chemical Resistance | Fair (sensitive to solvents) | Good | ABS |
| Surface Finish | Good (matte or gloss) | Excellent (Class A) | ABS |
| Formability | Excellent (widest window) | Very good | HIPS |
| Printability | Excellent (no treatment) | Good (may need primer) | HIPS |
| Heat Resistance | Up to 70–75°C | Up to 80–105°C | ABS |
| Food Contact | FDA compliant grades | Limited FDA grades | HIPS |
The simple rule: if your application needs superior impact resistance, chemical resistance, or a Class A painted finish — choose ABS. If cost, formability, and printability are the priorities — HIPS is your material.
The Formpack Advantage
We extrude HIPS sheets from pellets — no middleman, no minimum sheet orders. Custom colors, multi-layer co-extrusion, and food-contact grades available on demand.
From raw HIPS pellets to finished, trimmed, assembled parts — all under one roof. This eliminates supply chain complexity and delivers the lowest total cost.
From 0.5mm packaging trays to 6mm equipment housings — we handle both thin-gauge and heavy-gauge HIPS forming on the same production floor.
Serving USA, Europe, Middle East, and India. Export documentation and freight coordination handled by our logistics team.
Related Resources
Send us your drawings or 3D models. We'll recommend the right HIPS grade, provide a DFM review, and quote your project — typically within 48 hours.