Providing THERMOFORMING expertise since 2004

Forming Solutions, Inc. specializes in new product design and engineering for the thermoforming industry. We are problem-solving engineers, not sales people. With decades of real-world experience in the industry, we are dedicated to finding the best solution for every situation. We consult and collaborate with our customers through every phase of development, including design, engineering, prototyping, tooling and production. Our goal is to exceed your expectations.

Our Services


Providing highly collaborative thermoforming expertise, to produce timely solutions.


Taking idea generation, often “napkin sketches”, and applying creative product development in a 3D solid CAD world, through concept creation and product finalization. This development often includes dimensioned prints, 3D pdf’s, E-drawings or renderings.

3D Scanning

Our 3D scanner captures existing component geometry in order to import into a 3D CAD environment, used for reverse engineering, quality assurance, or analysis.


Utilizing finalized CAD geometry to machine “soft tooling”, typically out of REN shape, urethane or aluminum, which is used to produce sample products for fit, form and function testing.


Our engineering services include: developing manufacturable production tooling, secondary tooling and manufacturing processes (which are used for small or large volume production runs).


We use industry leading technology and techniques to CNC precision tooling, aimed at driving down lead times.

Industries We Serve

Medical packaging

Autoclave (steam)
ETO (gas)
Gamma (radiation)

food packaging

Deli Trays/Lids
Cookie Trays

Retail Packaging

Box Inserts


WIP Trays
Shipping Trays
Dunnage Trays
Custom Products

Store fixtures


Contact Us

Bemidji Location

Maple Grove

What People Are Saying

“First parts showed up this morning and we were very impressed with the resolution/fidelity of them, much nicer than any of our previous iterations [from previous supplier]. We're really optimistic now about this next batch from the improved tooling [FSI supplied].”

- Joel

“I thought it was about time I sent you an email that has no urgent request, no favors to ask and and no help required.

I just wanted to send a quick note to say thank you. You are just absolutely incredible partners and we are just so thankful for all of your support. Thank you!” 

- Tiffany

“Scott -- That mirror design worked out great. The products is on the market and it exceeded our customers' expectations. The fit was perfect. Thanks again!”

- Mark

"Perfect, thank you for all your help!  You are a rockstar!"

- Ashley