Deep drawn parts are custom-made and designed individually in a CAD format. Before a deep drawing tool is manufactured, a customer approval process of the CAD data or the derived, dimensioned PDF drawing takes place.
Sarah Guaglianone
Updated on June 24, 2026
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When referring to design data in plastic thermoforming, it means the CAD (Computer-Aided Design) file or the dimensioned drawing derived from it (often in PDF format) of the finished end product, in this case the thermoformed part.
When creating the data, both customer requirements and Design for Manufacturing (DfM) recommendations from the thermoformer or toolmaker are incorporated.
The design of the plastic thermoformed part serves as the basis for creating the thermoforming tool from aluminum. Once the tool is created, the next step is sample approval.
formary usually develops the product and therefore the design data completely from scratch based on customer requirements. Sometimes, however, customers also provide finished CAD data for the thermoformed part. This happens either when the plastic thermoformed part already exists in the company and is being requested again, or when the internal design department has created a proposal.
At formary, construction data is always provided to customers in the form of 2D drawings in PDF format and 3D data in STEP format.
STEP (Standard for the Exchange of Product model data) is a file type that enables the exchange of 3D models between CAD systems, regardless of which system the model was created on.
The technical drawing includes detailed information about:
A precise and careful review of the construction data is crucial to ensure that the thermoformed parts meet the desired requirements in terms of functionality, quality, and design.
To ensure that the created deep draw design meets the requirements and guarantees functionality, the following factors must be carefully considered:
The tolerance-compliant adherence to length dimensions (e.g., length x width x height) is always relevant to ensure that the final product meets the desired specifications. It should be checked whether the construction data were created with dimensional accuracy according to the agreed DIN ISO 2768 length measurement standard.
Nesting geometry is particularly crucial for plastic trays. The following questions must be addressed:
The construction data should therefore provide clear information on the conditions and tolerances that apply to the nesting geometry of the plastic deep drawn parts. This means the parts should be designed to make optimal use of the available space while ensuring smooth production flow.
Covers require specific data on the installation situation. The installation situation refers to the integration of the thermoformed part into the overall product or overall assembly of the customer's product. This is important to ensure that the part fits seamlessly into the intended environment and meets all assembly requirements. Therefore, it is necessary to check:
Different plastics have different properties and are suitable for different applications. The material specified on the drawing should therefore be checked for accuracy.
More information on plastics can be found in Materials.
The initial material thickness refers to the thickness of the plastic sheet or roll used in thermoforming. The initial material thickness was determined during quote creation based on technical criteria and can therefore be compared with it.
If multiple initial thicknesses are sampled to achieve the optimal stability and geometry result, the final design drawing is updated accordingly to the chosen solution.
For the creation and review of design data, the process looks like this: Requirements - Design - Data Approval - Sample - Sample Approval - Series.
In detail, project planning in thermoforming proceeds roughly in the following steps:
Enter your requirements in the configurator and send your inquiry to formary. You will receive an offer within 24 hours.
In the second step, you have two options:
Depending on your timeline, you will receive samples from the appropriate option. There are 4 options available, depending on the purpose of the samples:
More information on the advantages, disadvantages, and applications of the different samples can be found under Prototypes and our blog article on Rapid Prototyping.
After successful sampling, we start series production. Depending on your material, the chosen tool design, the machine type for production, and the quantity, the lead time is approximately 3-5 weeks from approval/order receipt to delivery of your series.
Design data for the thermoformed part is therefore not only created for the manufacture of the tool but especially for the customer's review of the end product. At this stage, any additional or previously overlooked requirements can be easily identified and incorporated into the design. This ensures an efficient sampling and project process.
formary ensures that a competent contact person is available to you throughout the entire project to clarify questions. Test it yourself now and request your plastic thermoformed part digitally. Configure now.
Design data refers to the CAD files or derived dimensioned drawings of the thermoformed part. It contains all information needed for manufacturing, sampling, and series production, such as dimensions, material, radii, draft angles, cavity geometries, and installation situations.