Duo Form Plastics

What Duo Form Plastics does

Duo Form Plastics (DBA Duo-Form) is a U.S. heavy-gauge plastic thermoforming manufacturer founded in 1968 and headquartered in Edwardsburg, Michigan. The company operates a single 250,000 square-foot manufacturing campus across five buildings on 27 acres, equipped with 27 thermoforming machines, three 5-axis CNC machines, four Fanuc robot trimmers, four large-format industrial printers, and a 120" custom coating system. Its core offering is custom thermoformed ABS and polycarbonate parts produced in thicknesses from .030" to .500" with sheet sizes up to 140" x 108", supplied under an ISO 9001:2015 certified quality management system.

Duo-Form serves six industrial verticals — Recreational Vehicles (primary, with products specified into an estimated 85% of RVs on the road), Electric Vehicles, Powersports, Work Trucks, Mass Transit, and Agriculture — through direct B2B OEM relationships with quote-based, multi-year contract pricing. A parallel B2C channel sells RV aftermarket replacement parts (shower pans, tubs, surrounds, skylights, skylight shades, sinks, accessories) and the Duo-PETS branded consumer products through a company-operated e-commerce storefront. The company is privately held with no disclosed parent, institutional investors, or funding rounds; leadership is led by President Shelly Ditmer, VP of Operations Mike Gonser, and Product Development Manager Dave Rheinheimer.

A key differentiator is Duo-Form's adoption of additive manufacturing for tooling: a 3D Systems EXT 1270 Titan Pellet printer produces thermoforming molds at 30-40% of traditional ceramic mold cost and in as little as 3 days versus 4-6 weeks conventionally. The company also runs a proprietary 90% recycled ABS material line, recycled 4.2 million pounds of plastic in 2022, and holds ASTM E84-18b surface burning characteristics compliance. Recent strategic moves include a 2021 building addition, the May 2021 launch of the Duo-PETS consumer sub-brand, an exclusive October 2021 partnership with Specialty Recreation, and the February 2024 completion of a dedicated Design Center with a fourth industrial printer.

Name

Duo Form Plastics

Legal name

DUO-FORM

Website

https://duoformplastics.com

Company type

Private

Founded year

1968

Operating status

Operating

Headcount range

51–100 employees

Short description

Duo Form Plastics is a U.S. heavy-gauge plastic thermoformer founded in 1968, supplying custom OEM parts to RV, electric vehicle, powersports, work truck, mass transit, and agriculture manufacturers from a 250,000 SF Michigan facility, alongside a direct-to-consumer RV aftermarket and pet products e-commerce channel.

Ownership category

akta.pro rank

Product category

Custom Thermoformed Plastic Parts

NAICS

All Other Plastics Product Manufacturing (326199), Other Plastics Product Manufacturing (32619)

SIC

Miscellaneous Plastics Products (3080), Plastics Products, Nec (3089)

akta.pro primary industry

Custom Thermoforming & Contract Manufacturing (IMANAHAI)

akta.pro secondary industries

Thermoformed Automotive & Transportation Components (IMANAHAE), Thermoformed Packaging (Food, Beverage & Consumer Goods) (IMANAHAA)

Keywords

• Heavy gauge thermoforming
• Custom plastic thermoforming
• OEM plastic parts manufacturing
• RV replacement parts
• Industrial mold making

Headquarters

HQ city

Edwardsburg

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B and B2C

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Supply Chain, Technology or R&D, Infrastructure, Marketing or Sales

Revenue model

1. B2B OEM Thermoformed Products: Custom thermoformed plastic parts manufactured for OEM customers in recreational vehicles, electric vehicles, powersports, work trucks, mass transit, and agriculture industries. Revenue generated through long-term partnerships with manufacturers requiring custom-designed parts and components.
2. RV Aftermarket Parts & Accessories: Direct-to-consumer sale of replacement RV bath products (shower pans, tubs, surrounds, sinks), skylights, skylight shades, and accessories through e-commerce platform. One-time product purchases with no subscription component.
3. Pet Products: Sale of Duo-PETS branded products including RV screen door protectors and pet carriers/accessories. Launched in 2021 as a new product division targeting RV pet owners.

Pricing tiers

Go-to-market motion2 records

Distribution channels2 records

Marketing channels5 records

Core offering

Duo Form Plastics is a heavy gauge plastic thermoformer that designs, engineers, and manufactures custom thermoformed parts for OEM customers across RV, electric vehicle, powersports, work trucks, mass transit, and agriculture industries, operating 27 thermoforming machines in a 250,000 SF facility. The company also sells RV aftermarket replacement parts (shower pans, tubs, surrounds, skylights, sinks, accessories) and Duo-PETS branded pet products directly to consumers through its e-commerce storefront, offering turnkey services from design and engineering through mold making, thermoforming, assembly, and finishing.

Product overview

Duo Form Plastics is a full-service thermoforming company offering a comprehensive portfolio of products and manufacturing services. Their core product lines include RV aftermarket parts (shower pans, bath tubs, shower surrounds, skylights, skylight shades, sinks, and accessories), pet products under the DUO-PETS sub-brand, and industrial thermoformed components for electric vehicles, powersports, work trucks, mass transit, and agriculture. They provide turnkey manufacturing services encompassing design & engineering, mold making & tooling (including 3D printed molds), thermoforming, assembly & finishing, and value-added services such as graphic design, custom coating, and printing. The company operates a 250,000 square-foot facility with 27 thermoforming machines and emphasizes sustainable manufacturing with 90% recycled material content in proprietary products.

Differentiator

Problem solved

Functional benefit

Brands

• Duo-PETS: Pet products sub-brand launched in 2021, providing American-made pet products and accessories including hard-sided luggage for pets, RV screen door protectors, and pet beds designed for camping and RV travel.

Products and services

• RV Shower Pans

Quantifiable outcome

• Thermoformed ABS sheet weighs 20-25 percent less than fiberglass molded parts, reducing overall vehicle weight and improving gas mileage
• +5 more outcomes

Named customers1 record

Segments6 records

Ideal customer profiles3 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

Four partnerships are on record, tiered core and minor.

• Specialty Recreation, Inc.coreStrategic or Co-development Partner · 1 October 2021Duo-Form announced Specialty Recreation as an exclusive partnership. Specialty Recreation is a key player in the RV components industry. The exclusive partnership allows for collaborative development and distribution of thermoformed plastic products.
• Wood TV / Clear the SheltersminorGTM or Marketing Partner · 1 August 2021Clear the Shelters sponsorship announced on National Dog Day, August 2021. Community engagement and pet-focused marketing partnership.
• 3D Systems (Titan 3D Printers)coreTechnology or Integration · 1 July 2021Partnership with Titan 3D printers (now division of 3D Systems) for extrusion 3D printing technology. Duo-Form uses 3D Systems EXT 1270 Titan Pellet 3D printer to produce thermoforming molds faster and more cost-effectively. The partnership enables production tooling using glass-filled PC pellets that withstand thermoforming process.
• Rollin' on TVminorGTM or Marketing Partner · 1 June 2021Branded sponsorship of the longtime RV lifestyle program 'Rollin' on TV' (ROTV) to reach RV enthusiasts and consumers.

Scale indicators9 records

Recent moves9 records

Expansion highlights4 records

Others

• Lippert Components: Leading supplier of components to the RV industry including chassis, furniture, and bath products. Direct RV-channel overlap with Duo-Form as adjacent buyer/seller in the same OEM ecosystem.
• Winnebago Industries: Major RV OEM and direct end customer for Duo-Form's thermoformed bath and interior products. Ecosystem participant rather than competitor, but a key demand-side signal for Duo's primary segment.
• Patrick Industries: RV and marine components supplier serving many of the same OEM customers as Duo-Form. Not a thermoforming peer but a relevant ecosystem participant and potential customer overlap.

Broad incumbents

• Pactiv Evergreen: Major North American manufacturer of thermoformed and molded fiber packaging. Comparable in thermoforming process but operates at materially larger scale focused on packaging end markets.
• Sonoco Products: Large global packaging and plastics manufacturer with significant thermoformed packaging operations. Comparable in plastics processing but at significantly larger scale and broader portfolio.

Direct peers

• Placon Corporation: Custom thermoformed plastic products and packaging across consumer, medical, and industrial segments. Comparable in custom thermoforming process and broad vertical exposure.
• Sika Automotive: Subsidiary of Sika AG supplying acoustic, reinforcing, and thermoformed/foamed plastic components to automotive OEMs. Directly comparable in automotive thermoformed components.
• Brentwood Industries: Custom thermoformed plastic products for industrial, water, and HVAC applications. Overlaps with Duo-Form in heavy-gauge thermoforming and custom contract manufacturing.
• Spencer Industries: Custom thermoformed plastics manufacturer serving RV, transportation, medical, and industrial markets. Directly comparable to Duo-Form in process, customer verticals, and heavy-gauge thermoforming capabilities.
• Mack Molding: Contract manufacturer offering custom thermoforming, injection molding, and assembly services. Comparable turnkey contract-manufacturing model serving industrial OEM customers.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• YouTubeyoutube.com/channel/UCbeeUx2KU09EArqxWM1hQ7g
• Facebookfacebook.com/duoformplastics
• Instagraminstagram.com/p/B2l_74Sh1QA
• Pinterestpinterest.com/duoformplastics
• LinkedInlinkedin.com/company/duoform-plastics

Compliance4 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles3 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Duo Form Plastics