thermoforming projects

Custom Pallet Forming

Clamshell Thermoformed Trays for

Heavy Industrial Pumps - Cad Models

These custom pump "clamshell" trays are designed so the bottom tray also serves as the top — simply flip it over and rotate 180° to create the matching lid. The interlocking feet allow safe, stable stacking of multiple layers. Each tray securely nests multiple 250+ lb pumps with precision-fit cradles and touch points that support the pumps.

These heavy-duty custom trays are designed for efficient nesting and stacking.

  • Empty trays nest directly on top of each other with aligned stripes.

  • Loaded trays (with customer parts) are rotated 180° when stacked, creating a visible staggered / zigzag stripe pattern.

This simple visual system allows operators and material handlers to instantly tell if a stack contains parts without opening it — making FIFO (First In, First Out) flow effortless and reducing errors in high-volume manufacturing.

Thermoformed Trays
Smart Stacking & FIFO Visual Management

Thermoformed Steering Gear Tray

          Precision Pocket Design          

Empty view showing the detailed custom cradles and support points engineered to securely hold heavy steering gear assemblies.

Steering Gears Shown in Thermoformed Tray

The same tray loaded with customer steering gears. Every component sits perfectly in its designed pocket for protection during shipping and handling.

thunder-volt lightning

HIGH PERFORMANCE RACE KART

Electric Go-Kart Body Design – 2016

I designed the full body for this electric go-kart while working at ThermoFlex in Morrison, TN. The client allowed me to start with their newly manufactured Go-Kart frame, to create a classic, traditional kart look using HMWPE body panels — which includes one-piece main sides and back, nose cone, and steering shroud.

Built for Amusement Products in Chattanooga, these karts feature 4 racing speeds and can reach 60+ mph. I’m especially proud that my daughter got to drive one on the track at a bowling alley in Columbia, TN.

Thunder-Volt Lightning Seat Design

While freelancing out of ThermoFlex, I designed a new driver’s seat for the Thunder-Volt Lightning high-performance electric go-kart. Using SolidWorks surface modeling, I created the ergonomic seat shape and CAD model for the tooling (wood pattern/mold) for the thermoforming process.

The project went from concept CAD model all the way to a full-scale physical mold — delivering a comfortable, race-ready seat that matched the kart’s sporty style.

CAD DESIGN MODEL

WOOD PATTERN / MOLD