Custom Thermoforming
Custom Thermoforming
Overview
Packaging Developed Around Your Product
AVI Global Plast develops custom thermoformed packaging for products requiring a different footprint, cavity layout or pack geometry. In-house material production, tool development and thermoforming at our Daman facility connect your packaging brief with the manufacturing process.
Built For
Custom Formats for Product-Specific Requirements
Share your product dimensions, handling needs and expected quantity so AVI's team can assess the material, tooling and production requirements.
Formats Beyond the Standard Range
Discuss packaging requirements that call for a different size, shape, depth or cavity arrangement.
↗ Discuss This ApplicationProduct-Specific Formats Beyond the Standard Range
Technical Window
Define the Custom Pack Your Process Needs
| Process | Material preparation, tool design and thermoforming coordinated at AVI's Daman facility |
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How a Custom Format Gets Developed
From Product Brief to Finished Pack
Custom development brings together material selection, tooling, forming and agreed validation checks. AVI's team reviews each stage against the product, packing process and finished-pack requirements.
Step 01
Material & Sheet Production
Select the material, thickness and appearance around the pack's forming and performance requirements. Material specifications guide sheet production for the proposed format.
- Intrinsic Viscosity
- Clarity
- Thickness
- Colour
Step 02
In-House Tool Development
Tooling is developed around the agreed dimensions, cavity arrangement and draw depth. Initial samples help assess the design before progressing to production.
- Forming Tools
- Cutting Dies
- Initial Sampling
Step 03
Printing & Lamination
Where required, printing or lamination is incorporated before forming. Artwork placement, material compatibility and forming behaviour are reviewed for the selected construction.
- Offset Printing
- Lamination
- Print Registration
Step 04
Thermoforming & Cutting
The sheet is formed and cut to the required geometry. Initial samples are checked against the agreed dimensions and layout before production proceeds.
- Pack Geometry
- Cavity Layout
- Cutting
- Initial Sample Review
Step 05
Quality Validation
The finished pack is assessed against the agreed specification. Dimensional checks and application-specific tests, such as seal-strength or drop testing, are included where required by the brief.
- Dimensions
- Seal Strength
- Drop Performance
- Batch Documentation
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