Custom heavy-gauge thermoforming provider Profile Plastics received two awards from the SPE Thermoforming Division for its work in developing the device.
LAKE BLUFF, Ill.—Profile Plastics Inc., a specialist in custom heavy-gauge thermoforming for more than six decades, is known for producing highly cosmetic, close-tolerance parts that meet increasingly demanding standards in high volume for OEM customers.
The company has been honored with more than 40 parts awards from the Society of Plastics Engineers (SPE) Thermoforming Division. Last May, Profile earned two of those awards for its help in developing a new medical device—a multi-part assembly that provides a durable, yet highly cosmetic cover for a customer’s advanced medical application.
The SPE Thermoforming Division recognized Profile Plastics with two awards for heavy-gauge pressure forming at its 2025 parts competition. The Division honored Profile for its work in developing this durable, highly cosmetic cover, which encloses the fluidics cart of a system used for a non-invasive tumor treatment procedure. (Image: Profile Plastics)
Both awards, presented at the SPE Thermoforming Division’s biennial Conference, were for heavy-gauge pressure forming. One, the People’s Choice award, was for best overall part at the show, as voted by conference attendees. The other was the Silver award in the pressure forming category, according to a release on Profile’s website.
The multi-part project includes six panels that enclose the fluidics cart of a system used for a non-invasive tumor treatment procedure.
Profile Plastics overcame design problems in re-engineering a project originally intended for injection molding. The final parts were made of 0.187-inch and 0.250-inch PVC/acrylic blend plastic with custom, molded-in color.
According to Profile, the central challenge was balancing patient safety and aesthetics with the airflow needs for the device.
“The design necessitated creating a unique, complex vent pattern on a curved surface,” the release stated. “Vents with proper draft and spacing were formed-in, then CNC machined on the back, resulting in no cutter marks on the front surface.”
Using a hidden fastening system for a clean transition between parts, the design provides tight-fitting alignment between panels. Profile also engineered two hidden magnetic holders on the device. These components hold tools during use, providing convenience for technicians while maintaining the aesthetics.
“Our design and production team exceeded all the OEM’s goals on this project,” said Mike Diaz, technical sales manager at Profile, in the release. “And we met the customer’s target price points.”