Custom Plastic Forming

What Custom Plastic Forming does

Custom Plastic Forming is a U.S. specialty plastics manufacturer operating from a 217,000 sq. ft. facility at 1735 Heilig Road, Salisbury, North Carolina. Founded in the late 1990s/early 2000s and operated as a subsidiary of Arrowhead Holdings (also referred to as Arrowhead Engineered Products, headquartered in Circle Pines, Minnesota), the company specializes in custom thermoforming — both thin-gauge (0.010" to 0.09" sheet thickness) and heavy-gauge (up to 0.500" sheet thickness, 9' x 11' platen, 60" draw depth) — using pressure forming and vacuum forming processes. It holds ISO 9001:2015 certification (since 2004), AS9100 compliance for aviation/space/defense, and FDA Current Good Manufacturing Practices (CGMP) conformance for food-contact packaging.

The company's offering is a turnkey platform that wraps thermoforming with design and reverse engineering (SolidWorks, ROMER digitizing arm), in-house toolmaking, multi-axis CNC routing (3-axis and 5-axis), 3D printing prototyping (Fusion3 F306 and Titan Robotics Atlas), fabrication and assembly, and downstream warehousing and managed inventory across 90,000 sq. ft. of dedicated space. Quality performance is anchored by a two-year average Defective Parts Per Million of 34 — described by the company as outperforming the industry threshold of 500 DPPM for "outstanding." Sustainability is positioned around a 98% recycling rate for eligible raw materials.

The business model is project-based and quote-driven: customers submit specifications through a contact form or by calling 1-800-757-1693, and sales engineers deliver personalized quotes (typically within 48 hours). The company serves industrial clients across the United States in six primary verticals — medical/healthcare, aerospace & defense, automotive, electronics, consumer products & retail, and commercial/recreation — with no disclosed revenue split. Distribution is exclusively direct (field sales plus phone-based inside sales), and pricing is custom per project with multi-year contracts available; no standard rate cards are publicly disclosed. Headcount is reported in the 51–100 range, and the company has been in continuous operation for 24+ years with no disclosed external funding events.

Name

Custom Plastic Forming

Legal name

Arrowhead Holdings

Website

https://customplasticforming.com

Company type

Private

Founded year

2000

Operating status

Operating

Headcount range

51–100 employees

Ownership category

akta.pro rank

Product category

Custom Plastic Thermoforming Manufacturing

NAICS

Plastics Product Manufacturing (3261), All Other Plastics Product Manufacturing (326199)

SIC

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

akta.pro primary industry

Custom Thermoforming & Contract Manufacturing (IMANAHAI)

akta.pro secondary industries

Industrial & Protective Thermoformed Packaging (Dunnage, Trays, Clamshells) (IMANAHAC), Thermoformed Electronics & Appliance Components (IMANAHAG), Thermoformed Packaging (Food, Beverage & Consumer Goods) (IMANAHAA), Thermoforming Tooling, Mold & Die Manufacturing (IMANAHAJ)

Keywords

• Custom plastic thermoforming
• Heavy-gauge thermoforming
• Thin-gauge thermoforming
• Plastic component manufacturing
• Pressure forming services

Headquarters

HQ city

Salisbury

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Operations

Revenue model

1. Custom Thermoforming Manufacturing: Revenue is generated through custom plastic thermoforming projects, including both thin-gauge and heavy-gauge thermoforming services. Customers submit project specifications and receive personalized quotes. Projects range from medical packaging and automotive dunnage to aerospace components.
2. Value-Added Services: Additional revenue streams from logistics and shipping, managed inventory programs, warehousing, fulfillment center services, fabrication and assembly, and testing and documentation services.
3. Toolmaking: In-house toolmaking capabilities for creating custom molds and tooling, providing complete customization for clients.

Pricing tiers

Go-to-market motion1 record

Distribution channels2 records

Marketing channels4 records

Core offering

Custom Plastic Forming manufactures custom thermoformed plastic components using both thin-gauge (0.010" to 0.09" thick) and heavy-gauge (up to 9' x 11', 0.500" thick) processes, including pressure forming. The company offers turnkey plastic forming solutions from concept to fulfillment, encompassing in-house design and engineering, 3D printing prototyping, toolmaking, CNC routing, fabrication and assembly, quality management, warehousing, and managed inventory services for industrial customers in aerospace, medical, automotive, electronics, and consumer products sectors.

Product overview

Custom Plastic Forming is a thin- and heavy-gauge custom thermoforming company offering a unified platform of plastic manufacturing services. The core offering centers on Custom Thermoforming Services, which includes both Thin-Gauge Thermoforming (0.010" - 0.09" thick) and Heavy-Gauge Thermoforming (up to 9' x 11', 0.500" thick). These are complemented by a comprehensive suite of in-house capabilities including Custom Plastic Design & Engineering, 3D Printing Prototyping, In-House Toolmaking, Quality Management Services, CNC Routing, and Fabrication & Assembly. Value-added logistics and fulfillment services (Fulfillment Center Services, Warehousing Logistics & Shipping, Managed Inventory, and Sustainability Services) complete the turnkey manufacturing ecosystem. The company operates from a 217,000+ sq. ft. facility and serves industries including aerospace, automotive, medical, electronics, commercial, and consumer products.

Differentiator

Problem solved

Functional benefit

Products and services

• Custom Thermoforming Services Primary thermoforming services providing both heavy-gauge and thin-gauge plastic forming capabilities for industrial customers across aerospace, medical, automotive, electronics, and consumer products sectors, with turnkey manufacturing solutions from concept to fulfillment.
• Thin-Gauge Thermoforming High-speed, high-volume thin-gauge thermoforming producing materials from 0.010" to 0.09" thick, suitable for medical packaging, assembly trays, and manufacturing applications across Kydex, PET/RPET, PETG, HIPS, PVC, PP, ABS, and HDPE/HMWPE materials.
• Heavy-Gauge Thermoforming Large-scale heavy-gauge thermoforming using three-station rotary pressure form machines capable of handling sheet sizes up to 9' x 11' and 0.500" thick with 60" draw depth, producing durable plastic parts for automotive dunnage, fitness equipment, aerospace applications, and other industrial uses across TPO, PETG, HIPS, PP, HDPE/HMWPE, ABS, PC, PVC, Kydex, acrylics, and acrylic-capped ABS materials.
• In-House Toolmaking
• Fulfillment Center Services Over 200,000 sq. ft. of facility space dedicated to inventory management, manufacturing, and fulfillment services including shipment arrangement and production run scheduling for clients.
• Warehousing, Logistics & Shipping 90,000 sq. ft. of on-site warehouse space supported by a local delivery fleet and third-party carrier coordination for comprehensive supply chain management and shipment services.
• Managed Inventory Custom stock-and-release programs leveraging 90,000 sq. ft. of warehouse space, customized delivery schedules, and supply logistics simplification for clients.

Quantifiable outcome

• Defective Parts Per Million (DPPM) averaging 34, compared to industry standard of below 500 being 'outstanding'
• +2 more outcomes

Segments6 records

Ideal customer profiles6 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature7 records

Partnerships

One partnership is on record.

• Arrowhead Holdings (Parent Company)coreOthersCustom Plastic Forming is operated by Arrowhead Holdings, with terms of use indicating Arrowhead as the parent company. Arrowhead Holdings is headquartered at 3705 95th Ave NE, Circle Pines, MN 55014. The relationship is a subsidiary ownership structure.

Scale indicators7 records

Recent moves6 records

Expansion highlights6 records

Direct peers

• Dordan Manufacturing: Custom thermoformer of clamshells, blisters, and trays with in-house design, prototyping, and tooling. Direct peer on custom/short-run thermoformed packaging for medical, consumer, and industrial customers.
• Profile Plastics: Custom thermoforming manufacturer providing heavy- and thin-gauge forming, 5-axis CNC trimming, assembly, and finishing. Highly comparable full-service offering and customer profile.
• Productive Plastics: Heavy-gauge thermoforming contract manufacturer focused on industrial equipment, medical, and transportation enclosures. Direct peer on heavy-gauge custom thermoforming with in-house tooling, finishing, and assembly.
• Formed Plastics: Custom thermoformer offering thin- and heavy-gauge thermoforming, design, and toolmaking services. Closely comparable turnkey thermoforming platform serving industrial customers.
• Mayflower Plastics: Heavy-gauge thermoforming specialist serving automotive, industrial equipment, and aerospace customers with large-format forming capabilities. Direct comparable on heavy-gauge, large-sheet thermoforming for industrial OEMs.
• Placon Corporation: Custom thermoformed plastic packaging manufacturer serving medical, food, retail, and industrial customers. Highly comparable to Custom Plastic Forming in process (thin-gauge thermoforming), vertical mix (medical/food/retail), and contract manufacturing model.
• C&J Industries: Custom plastics contract manufacturer offering thermoforming, injection molding, and assembly to medical, industrial, and consumer customers. Direct peer on multi-process custom plastics manufacturing.
• McClarin Plastics: Custom thermoforming and plastics contract manufacturer offering heavy-gauge forming, fabrication, assembly, and finishing. Direct peer on turnkey industrial thermoforming services.

Broad incumbents

• Pactiv Evergreen: Large-scale thermoformed and molded-fiber packaging manufacturer supplying food service and consumer goods customers. Broad incumbent with overlapping thermoforming capabilities serving food/beverage packaging.
• Sonoco Plastics: Diversified global packaging manufacturer with thermoformed rigid plastics used in protective and consumer packaging. Broad incumbent offering thermoforming as part of a wider packaging portfolio.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/custom-plastic-forming

Compliance3 records

Revenue estimate

Valuation estimate

Number of profiles

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 Custom Plastic Forming