What We Do:

API specializes in Thermoforming. This is a generic term for the process of producing plastic parts from a flat sheet of plastic under temperature and pressure. In the highest expression of the technology, thermoforming can offer tight tolerances and sharp detail. When combined with advanced finishing techniques, thermoforming can result in products comparable to those produced by injection molding at a fraction of the tooling cost.

Our manufacturing process consists of 4 main steps:


The First Step, DESIGN:

API understands the importance of good customer service. A Project Manager will be assigned to work directly with you to ensure the success of your project. Based on your input, the Project Manger will custom design your product(s) utilizing SolidWorks 3-d modeling software. We will supply you with 2-d drawing and/or 3-d CAD data for your review and approval.

Call today: 919-404-2080 or email us.  [TOP]

Form Tooling

The Second Step, TOOLING:

Once the design is approved, tooling construction begins.

There are several methods that we utilize to build thermoform tooling depending on complexity. Typically we start by CNC machining a wooden "pattern" directly from the 3-d CAD data. The wooden pattern can be used to produce a small number of preliminary prototypes for your review.

After preliminary prototype approval, this wooden pattern is used to cast a production temperature controlled aluminum mold.  [TOP]



Our main facility houses an array of specialized equipment for the purposes of forming, trimming, routing, bending, welding, and die cutting plastic.



  • 5 High Speed Rotary Thermoforming machines
  • 1 Double End Shuttle Thermofroming machine
  • 2 Single Station, High Speed Thermoformers
  • Sheet Capacity of 6 ft by 9 ft
  • Depth Capacity of 36 in
  • Sheet thickness from .040 in to .500 in
  • We use HDPE, HMWPE, ABS, PP, HIPS, PVC, PETG, PC, and Acrylic, etc.
CNC Trimming

CNC Trimming

  • Full Five axis trimming/routing capability
  • Eleven CNC routers (60 in x 120 in x 42 in capacity)  [TOP]
Quaility Control API is an ISO 9001 registered company. Our Quality Management System defines and controls the way that we operate our business.

This system ensures that your products are manufactured correctly each time. We utilize a 12' Titanium FARO arm to verify product dimensions and approve your product for shipment.

Trim and Fitting

The Fourth Step, ASSEMBLY:

API is very accustomed to secondary work and assembly. We have years of experience in die cutting, routing, machining, custom saw cutting, and many other secondary processes.

Our full time assembly department is skilled in assembling component parts using ultrasonic welding, mechanical fastening, and adhesive bonding.  [TOP]

Finishing Work
‘ Quality Products From Quality People ’

Powered by API, INC. · 535 Mack Todd Road, Zebulon, NC 27597
Phone 919-404-2080 Fax 919-404-2090