Unexpected hurdles are part of the job in manufacturing. Maybe sales volumes shift. Maybe your design is delayed. Maybe your budget gets cut or your injection molding tool estimate comes in far higher than expected.
At Ray Products, we hear these situations described every day, often starting with the same two words: “What if…?”
We’ve built our company to be a practical answer to those real-world questions. Below, we’ve grouped some of the most common ones we hear from engineers, purchasing, and project managers into four key categories: budget, volume, timing, and design. If you’re facing one of these challenges, you’re not alone — and you’re not out of options.
Budget & Cost Control
Q: What if landed costs have suddenly become higher than what was originally budgeted?
A: As a national manufacturer, Ray Products produces high-quality thermoformed plastic enclosures and custom-formed parts from our U.S.-based facility. That means you avoid overseas shipping, tariffs, and long lead times, giving you more control over cost and delivery.
Q: What if our CAPEX budget for tooling needs to be 1/10th of our current injection molding tool quote?
A: Production aluminum tooling for vacuum forming and pressure forming is typically 1/10th the cost of injection molding tooling. That makes thermoforming an ideal choice when capital expenses are under scrutiny, especially in the early stages of a product’s lifecycle.
Q: What if we need a custom enclosure molded in thermoplastic material, but injection molding volumes and tooling costs do not fit our budget?
A: The thermoforming process supports a wide range of thermoplastic materials, including high-performance options. With aluminum tooling and shorter setup times, you get reduced upfront costs and faster lead times without compromising on quality.
Q: What if sustainability is a requirement for my enclosure materials?
A: We can recommend resins with recycled content and identify options that align with your program’s environmental goals. Many thermoplastic materials also offer downstream recyclability.
Volume & Scalability
Q: What if the expected sales volume for our new product launch has been decreased?
A: The volume flexibility of vacuum forming and pressure forming makes it possible to start production in the high hundreds, not hundreds of thousands. And if demand grows, we can scale with you.
Q: What if my finished part size is 18” x 18”? Is that too large for thermoforming?
A: 18” x 18” is a great part size for the thermoforming process. In fact, Ray Products has the equipment and experience to mold parts up to 10 feet by 18 feet, ideal for large enclosures and structural applications.
Q: We are currently in urethane – or a low-volume process – and our volumes are increasing. Can pressure forming help?
A: By switching from urethane casting or other low-volume processes, you’ll see improved manufacturing speed, stronger part-to-part repeatability, and significantly lower costs.
Q: What if we need a supplier that can support launch volume to production?
A: Aluminum temperature-controlled tooling is the standard for production quantities, and we also offer launch-volume and bridge-tooling options to help you start quickly.
Timing & Support
Q: What if our CAD and 2D drawings are behind schedule, but the delivery date has not changed?
A: Ray Products can support you with engineering assistance and provide several pre-production options to get the finished product in your hands fast. We’re used to working in dynamic project environments, and we help keep things moving, even when the schedule shifts.
Q: What if I need to transfer a project or existing tooling?
A: Project and tooling transfers can happen for many reasons. Whether you’re changing suppliers or inheriting a legacy program, Ray Products will streamline the transition. We provide a detailed project schedule to help you resume production quickly and with confidence.
Q: What if I have never designed or purchased a thermoformed part?
A: You’re in good company — and we’re here to help. Sign up for a Tech Talk, and within one hour, you’ll gain a practical understanding of vacuum forming and pressure forming processes. It’s free, fast, and designed to make your next step easier.
Design & Performance Requirements
Q: What if we need custom molded parts that are NOT painted?
A: Vacuum forming and pressure forming allow for molding in color, including high-gloss and metallic finishes. This reduces post-processing and gives you a durable, consistent finish straight from the mold.
Q: What if I have multiple parts that need to be assembled onto a final unit, but I need help with alignment and attachment hardware?
A: Ray Products supports final assembly considerations as part of our project review process. In many cases, we can eliminate the need for fasteners by incorporating molded-in tabs or undercuts. When hardware is needed, we’ll help you select options that simplify alignment and reduce assembly time.
Q: What if our project has larger parts than our current supplier or technology can support?
A: Ray Products has the capability to mold parts up to 10 feet x 18 feet, supporting programs that require oversized enclosures.
Q: How can we reduce the number of parts used in our enclosure or device design?
A: Thermoforming’s ability to create large, unified structures makes it possible to replace multiple smaller pieces with one consolidated enclosure.
Material Solutions
Q: Our project needs to meet specific FAA, FDA, UL, or weatherable standards. Can you help?
A: Vacuum forming and pressure forming support a wide range of thermoplastic materials. We offer solutions that meet FAA low-smoke and toxicity requirements, FDA and food-handling needs, UL flame ratings, and weatherability performance, including UL 746C and F1 ratings.
Q: What if I am looking for a recycled or sustainable material solution?
A: Ray Products offers recycled and recyclable material solutions. We work with you to identify options that meet both environmental goals and performance requirements.
Q: What if I need a custom material color? Will it be as consistent as a painted part?
A: Today’s thermoplastic materials can be color-matched to your exact profile, including metallic effects. Using color spectrophotometers, gloss meters, and controlled-lighting environments, we verify that both raw material and finished parts match your specifications.
Q: What if I need a chemical-resistant material?
A: With a wide selection of thermoplastic options available, we can recommend materials resistant to chemicals such as bleach, hydrogen peroxide, isopropyl alcohol, peracetic acid, phenols, citric acid, glutaraldehyde, and more.
What’s Your What If?
You don’t have to settle for one-size-fits-all answers. At Ray Products, we know that every project comes with its own constraints — and we’ve built our approach to meet them head-on.
If you’re facing a tough question about cost, volume, timing, or performance, let’s talk. You might find the solution is closer than you think.