Thermoforming Technology for Noise and Vibration Control in Modern Equipment
Thermoforming is a proven and widely used manufacturing process known for producing lightweight, durable plastic components. But these days, it’s not just about shaping plastic. In fact, thermoforming technology has become indispensable for manufacturers who need to meet increasingly strict NVH (noise, vibration, harshness) requirements in modern equipment.
As machines and vehicles grow more complex and end users expect quieter, smoother performance, engineers are under pressure to control unwanted sound and vibration without adding weight or sacrificing durability. Thermoformed parts offer a compelling solution: custom shapes, material layering, and design flexibility that help dampen vibration and block noise where it matters most.
Let’s explore how thermoforming technology is being used to meet acoustic and vibration control goals, and why it’s an effective, scalable option for OEMs and equipment designers looking to stay ahead of the curve.
Engineering Considerations for Thermoforming Technology & NVH Components
Thermoformed technology allows for the shaping and strategic engineering of parts used for noise and vibration control. Getting the right NVH performance requires careful coordination of materials, part geometry, and integration techniques. Here are just some of the key considerations engineers factor into thermoformed component design:
- Material Pairing for Damping Performance — Selecting the right material stack is foundational to achieving effective NVH control. Thermoformed ABS or TPU skins can be combined with foam laminates, acoustic barriers, or composite backers to absorb or deflect sound energy.
- Geometry Optimization for Acoustic Isolation — The form of the part itself can dramatically impact how sound and vibration travel. Designing for baffles, airflow channeling, or decoupled panel structures helps reduce airborne noise and structure-borne vibration.
- Mounting and Integration Points — A well-designed thermoformed NVH part includes thoughtful mounting features that minimize the transmission of vibration at the point of contact. Flexible flanges, isolator tabs, and other integration techniques can reduce structure-borne noise while simplifying installation within a larger assembly.
- Lamination and Secondary Operations — To maximize performance, many NVH components include layered construction. Thermoformed skins can be laminated with absorptive linings or vapor barriers, depending on application needs. And secondary operations such as die cutting, bonding, or kitting help ensure that finished components are both performance-ready and production-efficient.

Design + Manufacturing Advantages of Thermoforming Technology
Fast Iteration Cycles
Compared to more tooling-intensive processes like injection molding, thermoforming allows for quicker, more affordable tooling modifications. This makes it easier to refine part geometry, integrate NVH materials, and move rapidly from prototype to validation, especially during early-stage product development or design revisions.
Scalability Without Cost Penalties
Thermoforming technology excels in low- to mid-volume production, where complex part geometries might be too costly to mold or machine. OEMs can achieve repeatable, high-quality parts without the upfront expense of high-pressure tooling, making it a scalable option for both niche products and growing programs.
Weight & Assembly Benefits
Thermoformed NVH panels are typically lighter than comparable metal or overmolded components, helping OEMs meet weight reduction goals. They’re also easier to integrate, fitting cleanly with surrounding systems and often designed to install without extra brackets or sub-assemblies.
Sustainability and Material Efficiency
Thermoforming produces less material waste than many subtractive or multi-step processes. Combined with the lighter weight of finished parts, this supports sustainability goals like improved fuel efficiency or reduced emissions over the product life cycle. Material efficiency also contributes to lower total production costs without sacrificing performance.
Real-World Applications of Thermoforming Technology
The use of thermoforming technology is invaluable to a number of high-performance equipment applications, including:
- Engine Enclosures with Integrated Noise Barriers: In industries like power generation or off-highway vehicles, custom-formed panels can be engineered to incorporate sound barriers alongside heat shields, offering robust protection while significantly reducing engine noise. The integration of these functions in a single, lightweight component streamlines production and enhances operational efficiency.
- Cab Interiors for Operator Comfort: These parts can be engineered to provide superior noise reduction while also meeting the durability and environmental resistance required for harsh outdoor environments.
- Fan Shrouds and HVAC Ducting: Thermoforming plays a key role in optimizing airflow and minimizing vibration transmission in commercial vehicles and gensets. Custom-designed fan shrouds and HVAC ducting made from thermoformed materials ensure better control over air distribution while isolating vibration-related noise.
All-State’s Engineering-Centric Thermoforming Approach
At All-State, we take a collaborative design approach, working closely with OEM engineering teams to ensure that each thermoformed component meets both technical and performance goals.
Our cross-functional support combines knowledge of NVH, thermoforming technology, and materials science. This enables us to select the optimal materials and design strategies to meet the complex demands of high-performance equipment, whether it’s for noise reduction, thermal resistance, or overall durability.
With precision tooling and a focus on efficiency, we also offer short lead times without compromising on quality. Our advanced capabilities allow us to seamlessly integrate acoustic layers and other materials directly into the thermoformed components, providing excellent noise control and ensuring long-lasting performance.
The result? Proven success in delivering complex thermoformed components for demanding applications, where both durability and acoustic performance are critical.
Partner with a Thermoforming Expert that Understands NVH
At All-State, we don’t just fabricate parts. We partner with you to solve your most challenging NVH and performance goals. With our deep engineering expertise and understanding of noise, vibration, and harshness (NVH) control, we’re here to help you create the most effective, durable, and acoustically optimized components for your equipment.
Whether you’re developing high-performance machinery, off-highway vehicles, or industrial equipment, we bring valuable insights and innovative solutions to every project. From design collaboration to manufacturing excellence, All-State is committed to being a trusted engineering partner throughout the lifecycle of your product.
Ready to elevate your NVH solutions? Connect with our team to discuss how our thermoforming capabilities can make a difference in your next project.