When to Use Shuttle Thermoforming for Your Next Project

Thermoforming comes in many shapes and sizes—and so do your parts. For projects where part size, complexity, or production volume doesn’t justify large-scale rotary or inline systems, shuttle thermoforming can be the perfect fit. At Arrowhead, in addition to Rotary thermoformers, we also have shuttle-style thermoforming machines we can use to produce a wide range of durable, custom-molded plastic parts for industries that need flexibility without sacrificing quality.

Let’s walk through what shuttle thermoforming is, when it makes sense to use it, and why more manufacturers are choosing this method for complex or large-format components.

What is Shuttle Thermoforming?

Shuttle thermoforming is a type of heavy-gauge thermoforming that uses a shuttle-style machine to move heated plastic sheets from an oven into a forming station. Unlike inline systems that continuously feed thin gauge material into a machine with limitations as to how much the process can be adjusted , a shuttle machine uses a slower, more easily customizable and afforable  process—making it ideal for larger or lower-volume parts.

Here’s how it works:

1. A plastic sheet is clamped and heated in an oven.
2. Once the sheet reaches forming temperature, it’s shuttled (slid or rolled) into the forming area.
3. Vacuum, pressure, or plug assist—sometimes a combination—is used to shape the sheet over or into a mold.
4. The part is cooled, released, and sent off for trimming or secondary operations.

Because of this flexible approach, shuttle machines are often used for large or thick plastic parts that can’t be produced on faster, higher-volume equipment.

When to Utilize Shuttle Thermoforming

Not every part is suited for high-speed rotary forming or the cost of injection molding. Shuttle thermoforming really shines when your project involves:

• Large part dimensions that don’t fit on common rotary or inline machines
• Lower production volumes where expensive tooling isn’t practical
• Prototype runs or early-stage designs that may require changes
• Highly customized geometries that benefit from hands-on control
• Complex or thick-gauge materials that require careful heating and forming

It’s also a great option when you need tight control over heat exposure and cycle times—common in parts where precision and appearance matter just as much as function.

Benefits of Shuttle Thermoforming

So why choose shuttle thermoforming over other processes? Here are some of the key advantages:

Lower Tooling Costs

Compared to injection molding, inline thermoforming or large-scale rotary thermoforming, shuttle forming requires less complex tooling. That means you save significantly on upfront costs—especially helpful in early production or specialty programs.

Flexible Mold Sizes and Fast Changeovers

Shuttle machines are designed for flexibility. They can accommodate a wide range of mold sizes and allow for relatively quick changeovers between runs.

Ideal for Thick-Gauge Plastic

When you’re working with heavier materials that need extra time and care to form, shuttle machines let us dial in the right temperatures and cycle times.

Support for Customization

Need to test a concept? Adjust a design? Shuttle forming makes it easier to incorporate changes mid-stream without delaying your project or driving up costs.

Scalable for Growth

Start small and scale when you’re ready. Shuttle thermoforming gives you a smooth path from prototype to production without locking you into a high-volume commitment.

Applications for Shuttle Thermoforming

Arrowhead has used shuttle thermoforming to build a wide variety of custom parts across multiple industries. Some common applications include:

• Vehicle panels and interior trim
• Machinery housings and enclosures
• Agricultural and construction equipment panels
• Industrial trays and returnable dunnage
• Instrument panels and dashboards
• Covers, lids, and access panels for OEMs
• Kiosks, consoles, and retail fixtures

Whether it’s a one-time project or an ongoing production need, shuttle thermoforming allows us to mold to your requirements—literally.

Best Materials for Shuttle Thermoforming

Shuttle thermoforming works with a wide range of thermoformable plastic materials, including:

• ABS – Great for structural parts with impact resistance
• HDPE – Resistant to moisture, chemicals, and abrasion
• TPO – Excellent flexibility and toughness across temperatures
• HIPS – Cost-effective and easy to form for general applications
• Polycarbonate – For parts requiring high strength and heat resistance
• Custom Laminates – Used for textured surfaces, branding, or added durability

Material choice depends on your part’s function, environment, cosmetic requirements, and budget. Our team can help you select the best fit based on your application.

Need Shuttle Thermoforming for Your Next Project?

Arrowhead’s shuttle thermoforming capabilities allow us to handle jobs that require precision, flexibility, and a collaborative approach to problem solving. Whether you’re producing large plastic panels, custom enclosures, or parts with complex contours, we’re ready to help.

With decades of experience in custom thermoforming, we’ve built our reputation on responsiveness, craftsmanship, and doing things the right way—from concept to production.