Expertise
For over 60 years, Merrill’s has been a thermoforming pioneer and through our own innovations we have helped the industry evolve. We know the design and production process backwards and forwards. Our unique approach starts by asking questions and making sure that we cover all the bases.
We know the design and production process backwards and forwards. Our unique approach starts by asking questions and making sure that we cover all the bases.
Thermoforming
Put simply, thermoforming receives a roll of plastic, heats it, and molds it into a perfectly formed package (many, many times over). Straightforward as it sounds, it is a complex process that must carefully consider heat transfer, pressure vacuum, and the dynamics of forming. We use precision microprocessor-controlled machinery to ensure we can produce huge quantities of flawless packages according to your validated design recipe.
Put simply, thermoforming receives a roll of plastic, heats it, and molds it into a perfectly formed package (many, many times over). Straightforward as it sounds, it is a complex process that must carefully consider heat transfer, pressure vacuum, and the dynamics of forming.
Custom Design
After your thorough Q&A session with us, our engineering team takes your objectives, specs, and ideas and then factors in contingencies like unit cost, long-term quality, and material handling requirements to come up with an initial package design. From that point forward, you will be consulted at every stage in an effort to boost quality, shorten turn around times, and minimize costs. Eventually, we’ll present an approved CAD design and 3D printed model that we can use to get an idea of size and style.
With cutting edge technology like 3D printers and CAD design, the Merrill’s Engineering team will consult you at every stage in an effort to boost quality, shorten turn around times, and minimize costs.
In-house Tooling
The design is only as good as the tooling. Any tiny flaw in the tooling means that mistake will be replicated over and over. We’ve developed a system of checks to ensure your tooling is flawless. With your approved CAD design, we can manipulate the geometry and export it to our Computer-Aided Manufacturing software (CAM) which allows us to write the mold program that can cut virtually any shape with both two and three dimensional surfaces in a matter of hours.
The design is only as good as the tooling. Any tiny flaw in the tooling means that mistake will be replicated over and over. We’ve developed a system of checks to ensure your tooling is flawless.
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Whether you know exactly what you need or still have a few questions about the specifics of your product or project, you've come to the right place.
