Start Your Project
Start Your Project

Custom Development

From Concept to Commercialization, Let’s Develop a Solution

Collaborate with our team of innovative experts to create customized material structures that perfect your thermoformed product’s performance. We work to streamline your development process by limiting the number of costly, time-consuming revisions and redesigns. Our time-tested approach drives your go-to-market strategy and steers your project to success!

Define the Specifications

In this critical first step of the production process, we define packaging requirements based on end-use product and environment, part design, processing, sterilization and distribution conditions. As we determine the optimal specifications for the desired performance of your product, many factors must be considered. Our team is ready and waiting with onsite support and consultative expertise to help you refine your requirements and select a solution that works for you.

Develop a Design

Once we define the specifications, we can cut to the fun phase: designing your custom-thermoformed part! Here, we weigh in on every factor, from processing and end-use environment to gauge tolerance, barrier specifications, shelf-life expectations, part geometry & handling and material attributes. We meticulously refine your material choices for flawless forming and performance, using your existing part designs or having our team of thermoforming pros sketch something brand new with you.

Create Renderings

After we define the specifications and develop a design, we craft a variety of renderings for a realistic portrayal of the finished part in full production mode— prior to mold design and fabrication. This stage’s goal is to limit the number of required revisions while evaluating part aesthetics and performance for end-user compliance.

Conduct Material Trials

Once the renderings are approved, we can jump into the trial stage, where your custom-designed sheet or rollstock is manufactured on a production-scale extrusion line. Our team of in-house engineers experiment with resin selection to hone in on key attributes like color, clarity, and additive integration from our specialty portfolio. We’ll stay close-by to consult with you on material selection and suggest features that further boost your brand.

On-Site Thermoforming Trials & Process Consultation

After material production, our team of thermoforming experts is available for onsite trials and process consultations. We’ve got decades of direct experience with the complexities of food and medical packaging, and we’ll be there to collaborate with you every single step of the way.


Once we coast through your trial phase, we’ll address commercialization in the approval stage of the development process. Let Impact Plastics take the lead on the logistical planning— interfacing with component suppliers and co-packers to ensure a fully-integrated supply chain experience that exceeds your expectations for quality and consistency.

Ready to Get Your Project Started With ICPG?