You may be surprised with what can be accomplished with vacuum forming.
Vacuum forming or vacuum thermoforming is a process that subjects a sheet of plastic to heat from one or both sides to bring it to a state that will allow it to be formed into a three-dimensional shape. While this process is rather simple, it has evolved over the last 60 years to become rather sophisticated in its simplicity.
With the use of wood, plastic, or aluminum molds (tools as we refer to them) the plastic sheet that is rigid and flat can become a shape rather quickly. The tooling is also fairly simple by design, which helps to control set-up costs for the launch of a new part or product line. Parts can be formed as small as your fingernail or larger than a boat. Items are being made daily that serve every industry from medical and consumer goods to transportation.