Case Studies
Thermoforming projects are not always easy.
Every thermoformed solution starts with a challenge—and is shaped through collaboration. Our case studies highlight how we partner closely with clients to turn complex requirements into innovative, high-performance thermoformed parts. From early concept development and material selection to tooling, prototyping, and production, we work side by side with our customers to deliver results that are practical, scalable, and tailored to real-world needs.
Explore how innovation, engineering expertise, and strong partnerships drive success across industries.
OUR WORK
Oasis Bench
Inspiration and Creativity
Meets Functionality
Lance Camper
Converting from Fiberglass to
Thermoformed TPO
Cobot Trimmer
Cuts CNC Lead Time and Cost
While Reducing Late Shipments
Oasis Bench
The Oasis bench takes its inspiration from the fantastic shapes created in the sand on a windy day. It is as much a captivating sculpture as an inviting functional seat. Its multi-sided design makes it a natural centerpiece and meeting point for both social interaction and quiet contemplation.
The bench adds a human and playful touch to any environment through its familiar, organic, and inviting shape. Perfect for interior or exterior placement in corporate, healthcare, hospitality, retail, and educational spaces, the bench seats up to eight people, its shape offering privacy as well as collaborative areas for groups. The bench measures 118”L x 58”D x 32”H.
Production of the bench was a challenge that pushed the envelope at each step of the manufacturing process, resulting in an amazing accomplishment in thermoforming. Production tooling, raw material selection, and forming were extremely difficult due to the complex shape, size, and material flow difficulty the design presented. Read more
Lance Camper
RV manufacturer Lance Camper reached out to Kal Plastics for assistance with converting its parts from fiberglass to TPO thermoformed plastic for
its very large exterior parts
Kal Plastics started with the nose of their extremely popular camper shell line, delivering tremendous value to Lance and the consumer. This was a difficult part to make with a new material that had just come to market. A. Schulman’s (now LyondellBasell) HGSR TPO was selected for the typical benefits afforded by TPO, and more specifically, its high-gloss, scratch-resistant product features.
Lance identified the front, curved surface area as the most critical area of the part.Structural and aesthetically pleasing design elements were incorporated, and several starting thicknesses were tested. Read more
Cobot Trimmer
Los Angeles-based plastics contract manufacturer deploys UR10e trimming cobot for a fraction of the cost and lead time of a CNC machine, cuts trimming time nearly in half, and reduces late shipments to under one percent—all while improving employee safety and growth opportunities.
Old technology requires a new approach. As the first known plastics thermoformer to use a collaborative robot for trimming, Juliet Oehler Goff, president and CEO of Los Angeles-based Kal Plastics, knew she was blazing a trail for others. “It was arguably kind of crazy because no one had ever done it before, so I took a huge risk,” she says, adding with a smile: “I don’t go to Vegas, but I gamble nine to five.” Read more