ShapeMaster’s Design Process:
We decided that this product would be accomplished best using vacuum forming. We chose vacuum forming because we can build prototype tooling and mold plastic sheets to test from a product concept. Then once proven, we can have a production tool built which allows us to run a very affordably made product–in this case, trays.
We did a few initial runs in glossy white before the customer decided that they wanted to add color to the design. We were able to find a plastic that could be extruded in two colors, one per side.
The customer also requested a decal for the side of each tray that could withstand an industrial dishwasher. We were able to accomplish this by sourcing bumper stickers instead of a traditional decal. They were an inexpensive solution that would be long-lasting and withstand the high heat and water from the dishwasher.