What Plastic Components does

Plastic Components Inc. (PCI) is a custom thermoformed plastic parts manufacturer founded in 1972 and headquartered in Elkhart, Indiana. The company specializes in heavy-gauge thermoforming, producing large structural plastic components up to 6 feet by 10 feet in a single form, using vacuum and pressure forming processes on thermoplastic sheets ranging from 0.060" to 0.500" in thickness. PCI serves manufacturers in heavy equipment and agriculture, transportation and mass transit, and medical device sectors as primary segments, with secondary exposure to automotive aftermarket, POP/display and retail, marine, HVAC, and gaming. The company emphasizes metal-to-plastic conversion, citing a 95% weight reduction example (a 718-pound steel belt guard converted to a 38-pound ABS part) and tooling costs that run at 10-15% of comparable injection molding. PCI was acquired by Khorporate Holdings, Inc. in 2022 and operates alongside sister entities K&S Mold and ABI Plastics under a unified Elkhart-based plastics platform.

The company operates on a project-based, quote-driven B2B manufacturing model with no publicly disclosed pricing tiers. Revenue is generated through custom manufacturing contracts covering materials, tooling, prototype development, and production runs, with typical tooling investment of $10,000 to $50,000 per project and first-article prototypes delivered in 15-20 working days. Technical differentiators include three 5-axis CNC trimmers, water-cooled aluminum tooling that cools parts up to 10 times faster than conventional tooling, pressure forming capability up to 60 psi, and integrated in-house finishing operations including CNC machining, painting, screen printing, mechanical fastener installation, and sonic welding. The go-to-market motion is engineering-led direct sales to OEMs and manufacturers, supported by content marketing (blog, case studies, eBooks), SEO, and a limited social presence on LinkedIn, Facebook, and YouTube.

PCI's commercial footprint is domestic and concentrated in the Midwest United States, with no stated international operations. The company announced a 37,000 sq ft facility expansion in January 2024, with 17,000 sq ft dedicated to relocating K&S Mold/ABI Plastics operations (adding 19 injection molding machines in the 60-500 ton range) and 20,000 sq ft reserved for future growth. PCI employs 11-50 people, while the broader Khorporate Holdings corporation employs 355 people including 50 engineers and 35 sales/marketing staff. No financial figures are publicly disclosed.

Name

Plastic Components

Legal name

Plastic Components Inc. (PCI, LLC)

Website

https://plasticcomponentsinc.com

Company type

Private

Founded year

1972

Operating status

Operating

Headcount range

11–50 employees

Short description

Plastic Components Inc. is a custom heavy-gauge thermoformed plastic parts manufacturer founded in 1972 in Elkhart, Indiana, serving OEMs in heavy equipment, transportation, and medical sectors with metal-to-plastic conversion solutions.

Ownership category

akta.pro rank

Product category

Custom Thermoformed Plastic Parts Manufacturing

NAICS

Plastics Product Manufacturing (3261)

SIC

Plastics Products, Nec (3089)

akta.pro primary industry

Thermoformed Automotive & Transportation Components (IMANAHAE)

akta.pro secondary industry

Thermoformed Electronics & Appliance Components (IMANAHAG)

Keywords

• Custom thermoformed parts
• Heavy gauge thermoforming
• Plastic parts manufacturing
• Metal to plastic conversion
• Industrial plastic components

Headquarters

HQ city

Elkhart

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Custom Thermoformed Parts Manufacturing: PCI designs, engineers, and manufactures custom heavy-gauge thermoformed plastic parts for customer-specific applications. Revenue is generated through project-based manufacturing contracts with pricing covering materials, tooling, prototype development, and production runs. Pricing varies based on part complexity, material selection, production volume, and tooling requirements.

Pricing tiers

Go-to-market motion1 record

Distribution channels1 record

Marketing channels6 records

Core offering

Plastic Components Inc. (PCI) designs, engineers, and manufactures custom heavy-gauge thermoformed plastic parts for OEMs and industrial manufacturers. Using vacuum and pressure forming, PCI shapes thermoplastic sheets (0.060" to 0.500" thickness) into large structural parts up to 6 feet by 10 feet in a single form, with in-house tooling, prototype development, CNC trimming, and secondary finishing operations supporting full project delivery.

Product overview

Plastic Components Inc. (PCI) offers a portfolio of custom thermoformed plastic part manufacturing services centered around heavy-gauge thermoforming. The core offering is custom thermoformed plastic parts, supported by integrated design and engineering, in-house tooling, prototype development, and finishing services. The company also offers complementary injection molding through its K&S Mold/ABI Plastics subsidiary. Key materials include ABS, HDPE, HMWPE, polycarbonate, polypropylene, and specialty grades like KYDEX. The company serves industries including automotive aftermarket, transportation, heavy equipment, medical, marine, HVAC, and POP/display. PCI's manufacturing capabilities handle parts up to 6 feet by 10 feet.

Differentiator

Problem solved

Functional benefit

Products and services

• Custom Thermoformed Plastic Parts Custom-manufactured heavy-gauge thermoformed plastic parts produced via vacuum and pressure forming for OEMs in automotive aftermarket, transportation, heavy equipment, medical, marine, HVAC, POP/display, and gaming industries. Parts range from sheet sizes up to 6'x10' and thicknesses from 0.060" to 0.500".
• Design and Engineering Services In-house design and engineering services matching the fit, form, and function of customer parts, including CAD modeling and design review for thermoformed part development.
• Tooling Thermoforming mold design and build services in multiple materials including wood, MDF, composite, cast aluminum, and machined aluminum, with water-cooled tooling options.
• Prototype Development First-article prototype parts typically delivered in 15-20 working days using wood, MDF, or 3D-printed soft tooling for design validation before committing to production tooling.
• Injection Molding (KSMolding) Injection molding services offered through K&S Mold/ABI Plastics subsidiary under Khorporate Holdings, with 19 machines ranging from 60 to 500 tons, complementing PCI's thermoforming capabilities.
• Finishing and Secondary Operations Secondary finishing operations including CNC trimming, die cutting, hand routing, surface enhancement processes, mechanical fastener installation, and sonic welding.
• Moving Your Molds / Tooling Transition Services Tooling transition services for customers switching suppliers or converting from metal stamping to thermoforming, including tooling assessment, prototype development, and production transition planning.

Quantifiable outcome

• 95% weight reduction (718 lb steel guard to 38 lb ABS part)
• +4 more outcomes

Named customers2 records

Segments8 records

Ideal customer profiles3 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Partnerships

Two partnerships are on record, tiered core and minor.

• K&S Mold/ABI PlasticscoreOthersK&S Mold (established 1978) and ABI Plastics are related companies under Khorporate Holdings. K&S Mold builds injection molds; ABI Plastics performs injection molding. PCI relocated and expanded K&S Mold/ABI Plastics operations into PCI's facility expansion (17,000 sq ft), adding 19 injection molding machines. PCI and K&S/ABI operate together to provide comprehensive plastics manufacturing capabilities.
• Purdue Solar RacingminorStrategic or Co-development PartnerPCI collaborated with Purdue Solar Racing to produce a large, transparent, lightweight windshield for their solar race car. PCI provided thermoforming expertise and manufacturing capability for a complex part requiring UV-stabilized polycarbonate with specific optical and weight requirements that the team's previous forming partner could not achieve.

Scale indicators6 records

Recent moves6 records

Expansion highlights4 records

Direct peers

• Penda Corporation: Penda is a heavy-gauge thermoformer serving truck, trailer, agriculture, and industrial OEM markets with large-format formed plastic components—directly comparable to PCI's core heavy-gauge forming business and customer verticals.
• Productive Plastics: Productive Plastics specializes in heavy-gauge thermoforming of large enclosures and structural parts for medical, industrial, and transportation OEMs, overlapping with PCI's industrial and medical segments.
• Universal Plastics: Universal Plastics is a heavy-gauge thermoformer producing large custom parts for aerospace, medical, and industrial customers using vacuum and pressure forming—closely mirroring PCI's process and part-size capabilities.
• McClarin Plastics: McClarin Plastics provides custom thermoforming, fabrication, and assembly of large plastic components for industrial and transportation customers, competing directly with PCI in heavy-gauge applications.
• Spencer Industries: Spencer Industries thermoforms large plastic enclosures and housings primarily for medical and industrial equipment OEMs, overlapping with PCI's medical and heavy equipment segments.
• Allied Plastics: Allied Plastics is a custom thermoformer producing heavy-gauge parts for industrial, transportation, and architectural end-markets, competing with PCI for OEM custom forming programs.
• Anchor Plastics: Anchor Plastics provides custom thermoforming and injection molding for industrial and consumer markets, offering similar integrated plastics services to PCI and its sister K&S/ABI operations.

Broad incumbents

• Plaskolite: Plaskolite is a large-scale North American manufacturer of thermoplastic sheet and formed products across many end-markets—a much larger, broader incumbent with overlapping thermoformed product offerings.
• Avient: Avient (formerly PolyOne/Spartech) is a large public polymer and specialty plastics company offering thermoformable sheet and finished formed parts across transportation, healthcare, and industrial—competing with PCI at scale across all primary segments.

Regional players

• Röber Kunststoffe: Röber Kunststoffe is a German thermoforming and plastics fabrication specialist serving European transportation, medical, and industrial OEMs—offering similar heavy-gauge forming capabilities as PCI but in a different geographic market.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks6 records

Key highlights7 records

Customer concentration

• YouTubeyoutube.com/channel/UCrz31mDGes-gTt03_157x6w
• Facebookfacebook.com/plasticcomponentsinc5742647514
• LinkedInlinkedin.com/company/plastic-components-inc-

Revenue estimate

Valuation estimate

Number of profiles

Profiles2 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 Plastic Components