Adding value.
Subtracting
waste.

Taking thermoforming from an art to a science is about understanding the relationship between man and machine. We custom-designed and built universal interfaces for every one of our thermoformers, so any person trained on one machine can work on any other.

Our arsenal of rotary and single-station thermoformers uses the latest software and controllers, ensuring a quality vacuum, pressure or twin-sheet part is produced consistently, every time — and is continually updated with the latest upgrades in heating science and mechanical requirements.

Non-value-added activities are systematically identified and eliminated, and all of our manufacturing cells are configured for continuous flow. Other tenets of lean — 6S, value stream mapping and Kanban — are employed daily. If lean is a journey, we're kind of like the trail guide.

Gone are the days when vacuum forming meant imprecise details and dull finishes. With more than four decades of experience, we do things with thermoforming that were previously only possible with injection molding, fiberglass or metal — at significant cost savings and reduced time to market.

Embossed logos. Premium gloss finishes. Structural foam insulation. Steel inserts. Deep draws. Color matching. Truck bed liners, belt shields and motorcycle fairings are just a few of many applications.

Twin-sheet forming can encapsulate metal components, produce parts with different colors on each side, and encapsulate insulation for substantial increases in structural strength and thermal performance — hollow or structurally sound parts with advantages over blow molding or rotational molding.

We also developed a patented selective twin-sheet process that adds a formed backing sheet only where it's needed — keeping costs down while reducing weight and adding strength. Why pay for extra material if you don't need it?

When existing manufacturing technology couldn't meet the demands of tomorrow's products, we engineered our own solution. Our team designed and built one of the world's largest twin-sheet thermoforming systems from the ground up — a manufacturing platform capable of producing parts up to 9 feet by 13 feet with depths reaching 6 feet.

Standing 20 feet tall and occupying more than 2,500 square feet of our Germantown, Wisconsin facility, this advanced system delivers 300 tons of twin-sheet forming force through servo-driven hydraulics while leveraging AI-assisted machine intelligence to maximize precision, consistency and efficiency. Featuring the first Bosch Rexroth 9-axis hydraulic cylinder control system in the United States, this investment reflects Hampel's commitment to pushing the boundaries of thermoforming technology — so our customers can push the boundaries of their products.

Our vertically integrated, in-house sheet extrusion capabilities give customers a competitive advantage through greater control, consistency and supply reliability. With the capacity to extrude more than 8 million pounds of plastic annually, Hampel produces high-quality sheet tailored to the demands of each application while maintaining tighter control over cost, quality and material availability.

By manufacturing our own sheet, we reduce dependency on outside suppliers, improve responsiveness, and deliver a more reliable production process from raw material to finished part.

Pressure forming takes vacuum forming to a level of precision previously only available through injection molding. Ideal for embossing logos, adding stiffening ridges and textured surfaces, the part takes on the detailed appearance of an injection-molded part — at significantly lower tooling costs.

We can form large parts up to 9' x 13' with depths reaching 6 feet — leading the industry in deep-draw capabilities. Our deep-draw process creates solid parts that previously needed to be built out of two or three individual components, cutting time, materials and cost.

The best example is Hampel's own Calf-Tel brand of calf housing, which reflects an actual 3:1 draw ratio.

Sometimes the surface finish needs to be flawless and glossy — body panels for tractors, lawn mowers, motorcycles and more. Processing cosmetic materials requires special forming, trimming and handling, but with more customers requesting premium-gloss appearances, we've made it a core competency — eliminating the need for painting while providing durable, weatherable surfaces.

With so many manufacturers focused on supply-chain consolidation, Hampel has the resources and agility to meet demand for a widening array of secondary operations:

• Assembly
• Adhesive bonding
• Decal application
• Kitting / packaging
• Kanban
• Bar coding
• Electronic Data Interchange (EDI)
• Logistics
• Design & engineering
• Pattern & tool design