ShapeMaster Specialties: Vacuum forming, Thermoforming, Injection Molding, and CNC Machining

ShapeMaster, Inc. specializes in plastic vacuum forming, drape forming, pressure forming, CNC machining, and plastic/metal fabrication. ShapeMaster, Inc. has provided quality goods made of plastic, metal, wood, foam and various resins since 1990. We work with engineers, designers, and inventors to take their print, sketch, or idea and turn it into reality. Our engineering/design team stands ready to assist in preparing CAD files that can be used in any of our processes: vacuum/thermoforming, custom plastic fabrication, CNC machining, plastic welding, and tool/mold building and more. Over the last 20 plus years we have used our problem solving skills to assist industries from agriculture to aerospace to medical to automotive in bringing their projects to fruition. Custom thermoforming, CNC machining, plastic/metal fabrication, drape forming, and other processes occur daily in our facility using plastic materials (ABS, PETG, CAB, UHMW, HDPE, etc.), metals (aluminum and stainless steel), as well as various resin, foam and wood products. Prototyping is not a problem. We average one new product every week. Production runs of vacuum/thermoformed, CNC machined, or plastic/metal fabricated parts are executed every day--from hundreds to thousands of parts. Our quality control department makes certain every effort is made to insure all parts meet the tolerances required by our customers—achieving much greater accuracy than thought possible using vacuum/thermoforming. Not only do we produce individual parts, but we assemble multiple components into one complete product. An example of this is our pottyhouse bank which incorporates plastic and wood and requires multiple thermoformed and fabricated plastic parts be glued together to form a finished unit. We welcome the unique and the creative!!

Please contact us with any project from a simple plastic tray to a complex water dispenser. We look forward to using our thermoforming, fabrication, CNC machining and design/engineering talents for you.


  • The newly designed wafer basket works great through both process lines we intended it for! Thank you!

  • It’s been a pleasure working with Shape Master! In the near feature, we are working on design for another PTFE basket for chemical wafer de-mounting. When I have more details to share, I would like to work with you again.

  • A franchise owner from a large restaurant chain needed to replace drain trays for their aging soda machines. He was unable to obtain repair parts, so he called us!   "Yes we got them and they are perfect!  Thank you very much for all the work you and your team did! "

  • Hi, Andy! I am very happy with the trays. They arrived in perfect condition, freight shipping was the right way to go. There will be more orders in the future. Have a great rest of the week. Take care. Best, Heather

  • Hello there. Just wanted to drop a line and thank you for making the bar risers for the Boulevard M50. I recently got a sweet deal on a nice 2009 M50 and saw on that you make risers for the bikes. I ordered a set from your Ebay store and installed them last week. Took about an hour and it went smooth. Very detailed instructions. I heated up the stock studs and they came right out and I Loc-tited the new ones in just for safety’s sake. Being a shorter guy (5’5”) the extra height now with the risers makes for a more comfortable riding position. Just wanted to let you know you have another satisfied customer! Regards, Mark

  • Hi Ken, Best wishes for the holidays to everyone at Shapemaster. Our trays this year are perfect- thank you so much for the modifications this year.

  • Our 3d printing service keeps a Grand Canyon vacation destination moving!  Say…just wanted to let you guys know that we finally got the time to install one of the parts you guys fabricated for us and it went in beautifully and works like it should.  I hope that the nylon wears well and that we get good service out of the component.  I will keep you posted. Anyway…so far-so good and I am sure that I will be sending more work your way. I have shared this project with a lot of people and everyone is very interested in your services. Thanks, Mike

  • I just installed my risers on my new-to-me 2006 M50.  I can now turn my bar all the way and still hold on to it!  Thank you so much for making these and almost as important, thanks so much for the detailed directions and photos. They sure made a difference in the installation!  If only all products were as well made and the directions as detailed.  Appreciate it! KRSalmon   You can find these riser blocks and more in our eBay store!

  • Dear ShapeMaster Crew, Thanks! I installed these in 30 minutes and they're are awesome! Great product! - eBay Customer These Boulevard M90 Handlebar spacer blocks can be found in our eBay Store  

  • "We have been working with ShapeMaster for several years and more recently have shifted many of our prototype orders to more repetitive production volumes. Ken has always been very helpful in the development of tooling, and making suggestions for efficient design of our vacuum-form components. He is very confident of his processes and capabilities, and his commitment to customer satisfaction is second to none. We will continue to utilize ShapeMaster and their products where feasible as we share common objectives in minimizing costs and maintaining the highest quality standards achievable."  

    David J. Brown, Purchasing Manager
  • "ShapeMaster has been an outstanding supplier for iCyt for many reasons. In addition to providing great service, quality parts, and meetingiCyt has benefited greatly from our relationship with ShapeMaster, and we look forward to working together on current and future projects. In addition to meeting our deadlines, ShapeMaster has provided iCyt valuable assistance in our parts design to help lower costs and reduce lead times."

    Rob Tichnor, C.P.M.
  • "What separates a good supplier from a bad one, or even better, good from great? I don`t have any problems distinguishing the good from bad, and the bad are easily eliminated. But, often the good maintain the standard compliance to your specifications. The great watch out for your interests. They offer integrity, follow through, networking, and an overall interest in your profitability. ShapeMaster has been my supplier and a customer for many years, and they have been ‘great’. They have provided product that exceeds specification done in a timely fashion. If something cannot be produced, a quick alternative source is recommended or called for review, and quite often, alternative materials are pursued to provide an appropriate profit margin affecting our bottom line. ShapeMaster`s follow through and diligence as a supplier and customer persuades me to continue to recommend them to others."  

    Ken Batty
  • "I couldn`t have gotten luckier when I stumbled onto ShapeMaster while searching for someone who could bring my idea to fruition. As a pediatrician by trade, and an independent inventor, I feared that getting reliable help would be a struggle. Some prototypers and manufacturers I approached neither took me seriously, nor treated me professionally. I waited on emails, call backs, feedback, etc. That wasn`t the case with ShapeMaster. When I received my first reply from ShapeMaster`s Ken Cooley and it simply said, "We can help," I knew that I had struck gold. Since that exchange, my experience has been ideal. The staff of each department has been prompt, courteous, and professional...which is monumentally appreciated! And in terms of production, the injection molded piece that ShapeMaster made for me, and the final product that they assembled is exactly what I imagined. Along the way I received feedback, samples, quotes, and even the final product when promised and as quoted - no surprises! ShapeMaster is a well run organization with the utmost integrity, pride in their quality work, and worthy of anyone`s trust. "

    Dr. Amr Megahed, (MD, FAAP)
  • When our client requested an intricate custom plastic tray, we turned to ShapeMaster and ShapeMaster turned our design into a reality! They communicated with us on every step of the project; we received the trays on time; and they were a big hit with our client. It was a win-win situation from design through production, and we’ll definitely rely on ShapeMaster for future orders.  

    James Reisigl, Reisigl Associates at
  • "I would like to take a moment and convey how impressed I am with ShapeMaster`s ability to meet the needs of my various projects. Supplied with nothing more than a rough sketch of what I was looking for, you and your team came up with exactly what I needed (even though I really didn`t know exactly what I needed). Given ShapeMaster`s ability to offer professional service on a personal (customizable) level, I can only see great things for the future of your company." -Kevin Bassilmington, Engineering Technician

    Kevin Bassilmington, Engineering Technician
  • Thank you for your help with our dispenser shroud project. Our inquiry was dealt with very effectively through the entire process. The product was delivered on time and matches exactly to what we have had manufactured in the past, for a fraction of the price! Thank you to everyone at ShapeMaster for a job well done!  

    Tom White
  • "Ken, we received the trays yesterday. They are working VERY well. Thank you for all your hard work on this project. Also, the way you designed the raised ridges on the bottom so plant flats sit slightly above the bottom of the tray has an extra benefit; the plant flats seem to slide quite smoothly when we rotate flats within a tray. Again, great job and thank you!"

    Debra Becker, Research Assistant I, Crop Traits & Discovery Department Portland, Oregon
  • Dear Ken, I wanted to drop you a note and thank you for your participation in the development and manufacturing of our”BAG-R-BOX Saddlebag Insert Trays” product. I found working with you very pleasant, informative and worthwhile. I also appreciate the professional manner by which you and your staff conduct business. The product has turned out just as I had envisioned it, when we first began discussing my idea. We’re very pleased with the outcome. The manufacturing process went smoothly and I have found not defects in material or workmanship amongst my inventory. The four-position mold that you are maintaining for me will make re-manufacturing in quantity a breeze. I look forward to working with you again soon.  

    Michael Tipps, CEO Glaive Products LLC
  • I`d like to thank you and your team at ShapeMaster for the PETG hemispheres you made for us. Our requirements were uncompromising-6.9 inches in diameter and perfectly spherical. ShapeMaster met those requirements with very high quality and in good time. We were impressed.

    William M. Hartmann, Professor of Physics Michigan State University
  • Simply stated, because of Shape Master, we now have a beautiful building which is as close to its original restoration as we could determine. You made five different molds and then created replacement parts from these which when we put them up became absolutely impossible to see as different from the originals. The ceiling was so severely damaged that we were concerned that it could never be repaired. The actual labor to repair the damage once we received the new panels from you was about 32 hours. This was well worth the cost and the result speaks for itself. There is simply no other way that we could find to accomplish this without you and the talent at your company. The building prior to this project had a suspended ceiling just under 8 feet high and the upper window sections could not be seen from the inside an don the outside they were simply covered in plywood and painted. You have no idea how much your company helped us. I’m at class now doing insurance updates but what you did for us is absolutely unbelievable. Somebody has to stop in Boscobel and see the results some day.  

    TRICOR Insurance
  • "The initial order for 2,000 trays was based off an educated guess - after using the trays I feel we may make another order in the very near future. With that being said that is not why I am really emailing you. The main reason for this is to extend my most sincere "thank you" to you, your company and anybody involved with this project for us. These trays exceed all expectations in both functionality and cosmetic quality overall. Absolutely outstanding!!! Thank you."  

    Joe Marullo, Finishing Department Manager
  • "I would like to take this time to thank ShapeMaster for being a vendor and supplier for Guardian West (Flex-n-Gate). During the past five or six years, ShapeMaster has been there for us. I would like to thank some of the employees – Ken, Pam, Darlene Wakefield, Mark Ploense, Jody, Deva, Ruth, and other faces I`ve seen, but don`t know their names. From molding polyurethane (rubber end caps) to 4-lb. density foam to other foam applications to fabrication of new products, I would recommend ShapeMaster for future needs in foam and plastics."  

    Mike Cotton, Maintenance Project Coordinator
  • "As an instructor at the Lake Land College Center for Business & Industry, I was tasked to design a manufacturing cell for our Manufacturing Skills Training Lab. We found ShapeMaster by recommendation of another area supplier. Ken Cooley and his team at ShapeMaster were very helpful in providing me with high quality finished pieces as well as reviewing the design of the pieces to insure good fit and operation. They went out of their way to ensure I was satisfied with the results."  

    Randy Strohl, Technical Training Specialist
  • ShapeMaster Crew, I got the tray and I`m very impressed with the quality, size, and price!! Plus, your customer service just can`t be beat!!! Thanks again.....and tell Andy that I said her customer service is outstanding!!!  

  • ShapeMaster Crew, Just got them on and went out for a test ride. They really make a difference! Install was fairly easy, but I was paranoid about cross-threading the bolts. With the left-over thread lock from the factory, it was hard to judge whether the bolts were going in correctly, but I got them in OK! I also added my own threadlock as per your suggestion. You made some excellent suggestions on your instructions. Covering the tank and forks is a no-brainer, but loosening the controls was a must! Also, I rolled the bars up a little bit per your suggestion, and that made the mod even better! The risers look great, and the seating position is much improved. All in all, great product that I will recommend to anyone with an M90/50 and any other model you make these for. As far as, riding in Vegas, we`re pretty much year-round. Summer gets hot, but other than that, it`s pretty mild. We`re in the mid-60`s for the next week, so you can bet I`ll be out there. Thanks again for the follow-up, and have a great New Year!  

  • Dear ShapeMaster Crew, I did receive my soap molds very promptly. It just took me a while to answer back to you. They are terrific!! I love the shape and weight. They work very well and make nicely shaped bars. Thank you for such prompt, friendly service.  

  • Hello Ken, It is a second year already since I have been using the risers. I bought them from you and I absolutely "forgot" about them because it was like they became part of my rider`s body - naturally comfortable!  

    Evgeny Vishnevsky
  • They are PERFECT. They actually make low speed easier to steer and much more comfortable in position with the stock drag bars. Beautiful job on them. The bike had pull backs on when I got it - and I put the stock bars back on. Left you very favorable feedback - thanks.  

    Bob H
  • Hey ShapeMaster Crew-Installed the risers yesterday, and went for a long ride today - they`re great, thank you!  

  • I appreciate your outstanding customer service. The risers arrived on Thursday; I installed them Saturday on my wife`s 2009 M50. She loves them and she was comfortable riding the bike all weekend. Now she doesn`t get a sore back or tired arms after riding a few hours. The directions were good, which I especially appreciated, and after heeding them had no problems making the upgrade. The tip: reusing the torch to heat the bolts to loosen the lock tite on the bolts was especially useful. Thanks alot. Excellent customer service!! Thank you for promptly taking care of me. Have a wonderful day.  

    Ike Digman
  • I have already installed them and love the position of the bars. The instructions were great. This was one of the best investments I`ve made for my bike!  

  • "Hey ShapeMaster Crew, I added the risers Thursday. Wow wow wow! I can actually look forward to riding my "M." And that`s the key word - ride. Not dread or suffer through or tolerate but ride :) Tell Ken I said thanks!"  

  • "Hi ShapeMaster Crew, I have fitted the risers to my M-90 and even though it was only 1”inch it has made a huge difference to the comfort of the riding position. The shape and color are a good match, the overall manufactured product is great. As others have had to do I also moved the clutch control in about 3/8”inch. I am very pleased with the modification and the simple fitting process"  

  • Hi ShapeMaster Crew! It’s right! I received the risers last Thursday but until yesterday I couldn't install them, but now it’s done! So sorry not to respond to you quickly. Well…in a few words it’s simply awesome. I tried the motorcycle this morning and I couldn't describe how much better it is now with the spacers. It gives you the only correct position to enjoy the driving of this motorcycle and it would be wonderful if every Suzuki M800 in the world could have a pair of these spacers. I only can say THANK YOU for your work and everything. You've spared me a lot of back pain and given me a lot of miles of enjoyment with my motorcycle. It maybe sounds corny but it’s only the truth. Thank you, thank you very much. P.S. be sure that I will talk with everyone of my biker friends about Shapemaster and the really professional people who work here.

  • Hi ShapeMaster Crew, Thank you for the letter—I just waited for the weekend to write you back….The risers were installed by my local Suzuki dealer(I did not take on myself to install this important part)—please, pass to Ken my thanks and respect! Today, I am even finding myself with “difficulties” to explain how comfortable I am feeling, just because I AM NATURALLY FEELING EXCELLENT—means, if I would get my bike first with these risers—I just would say “excellent,” everything comfortable! But I had time to drive without Ken’s risers, so I can compare. Just two days ago I realized I am not speaking about back pain—can you imagine?! I naturally felt so good with these risers that I even forgot about the previous pain—this is saying a lot! I think it is our (risers) happiness to have a person who is a rider himself, analyzing the performance, and making goods(because plus to everything he is also a skillful guy), which are improving our riding—I am speaking about Ken. Again, my respect and thanks! Do not forget—I am waiting for other developments…Thank you very much again, excellent idea and very well done!  

    Evgeny V., Very satisfied customer
  • Hi ShapeMaster Crew, Yes, I received my M50 risers and installed them on my bike the following day. The installation went smoothly and my motorcycle is much more comfortable to ride now than before. I think they’re a great product and would encourage others to try them. Regards, Paul Read  

    Paul Read
  • Hi ShapeMaster Crew, Just to let you know, I have them installed on my bike, and they are fantastic!!!!!! I also dropped the bars down one notch, which was suggested in the instructions. The difference is incredible. I’m sitting much straighter, and the front end of the bike seems much lighter and is easier to steer. The product and instructions, which came with it, are first class. I will be telling everyone I meet who has a bike like mine about these. A suggestion, how about making a sissy bar with luggage rack as your next project for the bike?  

  • I just wanted to let you know I installed my risers this weekend and went for a short ride. It is absolutely amazing how much of a difference those little 1 ½ inch risers make. I wish I had bought them earlier. Thank you for the help.  

    Tom Schultz
  • I got the bank and it is GREAT; Super Detail; Thanks-A-Lot!!!  

  • The risers fit perfectly. I followed the directions by applying heat to the studs and I had absolutely no problems installing them. The whole process took about 25 minutes. I personally put the handlebars forward over the headlight, so that the studs stood straight up. I folded up a towel to put between the headlight and handlebars. I went for a ride after installing them. I was very satisfied with the feel of the risers in the new seating position created. I sit much more upright. Definitely a 5 star product!  

  • "Hi ShapeMaster Crew. I have received the risers. I fitted them today, what a difference they make. I am very pleased with them and the high quality of the product. Thanks again!"  

  • “ arrived today Ken. Thanks...looks great…can`t wait to get it onto my M50! Great design...and I like the silver grill. Thanks!"  

    Dave Yates
  • "As a new and inexperienced inventor, I was completely clueless as to how to get started with my idea. You and your staff have been extremely helpful with the development and designing of my product, and I am more than thankful for that."  

    Mary Minneci, President

Why Choose ShapeMaster Inc.

Our People
Our Midwestern-based work force is comprised of people who maintain the production expertise, technical knowledge, competence, training, and creativity needed to effectively and efficiently serve our customers’ needs. We combine a passion to innovate with a passion to provide superior customer service, enabling us to deliver positive results which lead not only to the success of our customers but also to the success of our company.
The Way We Do Business
Our standard of excellence is based on the philosophy “Swear to your own hurt, and change not.” This refers to keeping our word when we commit to something, including pricing, quality standards, precision, delivery times, etc. Our team does whatever it takes to get the job done to keep our promise and exceed customer expectations, regardless of the effort, even if at our own expense. We know that word inevitably gets around with regard to how you treat customers. Words like flexibility, honesty, integrity, and dependability are associated with ShapeMaster’s customer relations and we work hard to continue this tradition. We’ve built our business and our reputation by exploring and understanding customers’ needs, discovering ways to meet those needs, and delivering exactly what our customers need when they need it.