Plastic Fabrication
Custom Plastic Fabrication Services
Our Plastic Fabrication Capabilities
CNC Plastic Routing
Calsak’s CNC routing cuts plastic sheet, rod, and tube stock to precise dimensions for projects ranging from single prototypes to full production runs.
CNC Drilling Services
Precision drilling creates clean, accurately placed holes in plastic materials for hardware mounting, assembly, and structural applications, across both small and large-volume orders.
Thermoforming
Thermoforming heats plastic sheet until pliable, then forms it over a mold into a custom shape — used for enclosures, covers, displays, and contoured components that can’t be achieved by machining alone.
Cold & Heat Bending
Cold bending shapes plastic at room temperature for simple angles; heat bending applies controlled heat for tighter radii and more complex geometries. Calsak offers both, matched to the material and application.
Polished Finish
A polished finish removes tool marks and haze from cut or machined edges, producing a clear, professional appearance for display, signage, and retail applications where visual quality matters as much as function.
Assembly & Kitting
Calsak assembles and kits fabricated plastic components into ready-to-install or ready-to-ship units, reducing the labor and complexity your team would otherwise handle in-house.
Industries We Serve
Marine & Boat Building
Trident® E-ABS and expanded PVC for hulls, cabinetry, and dock equipment engineered to withstand saltwater and harsh coastal environments.
Architectural Signage
Acrycast® acrylic and PolyGuard® polycarbonate combining aesthetics with all-weather durability for indoor and outdoor sign applications.
Construction
Lightweight, high-strength plastics and LumaTek® PVC boards for cladding, glazing, temporary structures, and permanent building components.
Printing & Graphics
LumaPrint® and Acryglas® substrates engineered for superior ink adhesion and color vibrancy across wide-format and specialty printing.
Also serving: Aerospace • Automotive • Medical • Retail Display • Data Center • Advertising & Art
Packaging & Delivery
Fabricated plastic parts are only as good as the condition they arrive in. Calsak pairs its fabrication services with custom-cut protective packaging and a dependable delivery network — so orders reach your facility ready to use, on schedule.
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Our Closed-Loop Recycling Program
Calsak operates a dedicated recycling business unit that processes both internal and customer plastic scrap. Material is sorted, ground, and pelletized on-site, then converted back into new products and sheet stock — a closed-loop system most fabrication providers don’t offer in-house.
Why Fabricate With Calsak Plastics
One provider, full process
Fabrication, finishing, packaging, and delivery under one roof — not handed off between vendors.
In-house recycling
Scrap from your project can be reclaimed through Calsak’s own closed-loop system, not shipped to a third party.
Volume flexibility
Equipped for single prototypes and large-volume production runs alike.
Since 1972, Calsak Plastics has operated as a plastic sheet, rod, and tube distributor and fabricator across 7 U.S. branch locations.
Frequently Asked Questions
What is custom plastic fabrication?
Custom plastic fabrication is the process of cutting, shaping, drilling, or forming plastic sheet, rod, or tube stock into parts built to a specific design or dimension.
What plastic fabrication services does Calsak Plastics offer?
Calsak offers CNC routing, CNC drilling, thermoforming, cold and heat bending, polished finishing, assembly and kitting, custom packaging, and closed-loop plastic recycling.
Can Calsak cut plastic sheets, rods, or tubes to size?
Yes. Calsak provides cut-to-size services for plastic sheet, rod, and tube stock, sized to your project’s exact dimensions.
Does Calsak Plastics offer plastic recycling?
Yes. Calsak runs a dedicated closed-loop recycling unit that processes internal and customer scrap into new sheet stock and products.
What industries does Calsak Plastics serve?
Calsak serves marine and boat building, architectural signage, construction, printing and graphics, aerospace, automotive, medical, retail display, data center, and advertising and art industries.
What’s the difference between cold bending and heat bending?
Cold bending shapes plastic at room temperature for simple angles. Heat bending applies controlled heat to achieve tighter radii and more complex shapes.
Can Calsak handle large-volume fabrication orders?
Yes. Calsak’s facilities support both small prototype runs and large-volume production orders with consistent quality.
Does Calsak offer assembly services in addition to fabrication?
Yes. Calsak assembles and kits fabricated components into ready-to-ship units, reducing downstream labor for customers.
Ready to Start Your Fabrication Project?
Tell us your dimensions, material, and application requirements — Calsak will handle the rest.
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