Patented battery cooling tubes
Thermoformed cooling tubes in PPE & PS blended material: UL 94 rated, electrically insulated, air-leak pressure and burst tested. Lighter than metal, engineered for EV and battery energy storage packs.
CUSTOM THERMOFORMING · PROTOTYPE TO PRODUCTION
Heavy-Gauge & Twin-Sheet Thermoforming, Built to Your Spec
Versa 3 engineers custom thermoformed components for OEMs — from prototype to production across ISO 9001 and IATF 16949 certified plants.Twin-sheet forming for hollow components with internal reinforcement or air channels.
Upper sheet: formed to the external geometry of the component.
TWIN-SHEET FORMING · EXPLODED VIEW / CONCEPTUAL
01 / ENGINEERING ADVANTAGE
What sets Versa 3 apart
Engineering beyond the formed part.
Prototype before tooling
Prove fit, material and assembly before committing to production tooling. Thermoformed or vacuum-formed prototypes, plus 3D printing (SLA/SLS/SLM/FDM), CNC and vacuum casting.
Application engineering
Components delivered ready to apply: adhesive-backed, die-cut or kiss-cut, or designed for robotic application lines.
One piece, not an assembly
Thermoforming, extrusion and in-mold decorating combined so a component ships as a single finished piece instead of parts to assemble.
Which process fits your part?
A starting point, not a final engineering decision.
02 / FORMING CAPABILITIES
Two processes. Your application.
Formed for the geometry, performance and assembly your part requires.
SINGLE SHEET / PRESSURE FORMING
Thick / heavy gauge
Equipment housings, machine guards, industrial shells and panels, structural trays, heavy-duty pallets. Pressure forming for sharper detail.
TWO SHEETS / ONE HOLLOW COMPONENT
Twin sheet
Two sheets formed into one hollow, lightweight, structurally strong component — ducting, tanks, industrial housings, structural pallets, and large covers with internal reinforcement or air channels.
Known as vacuum forming in Europe — same engineering, same plants.
03 / CERTIFICATIONS & PLANTS
Certified plants. Global reach.
Nearshoring options to shorten lead times.
The right material for the job.
Material selection support from our engineering team.
04 / HOW AN ENGAGEMENT WORKS
From your drawing to production.
ENGINEERING REVIEW
Let’s scope your part.
Send your drawing or part requirements for engineering review.