Forming & Fabrication
Precision Forming and Fabrication for Complex Thermoplastic Routing
Mercury Plastics’ forming and fabrication capabilities transform straight thermoplastic tubing into application-specific, production-ready components. By integrating bends, transitions, and secondary operations directly into the part, we help eliminate fittings, joints, and assembly steps that add cost, complexity, and potential failure points.
Water Line - Click Connex
Water Line - Click Connex
Water Heater Dip Tube
Refrigerator Water Line
Ice Maker Fill Asssembly
Water Dispensing
Ice Maker Fill Assembly
Ice Maker Fill Assembly
Drain Tube
What is Forming and Fabrication?
Integrated Bends and Transitions for Tight Routing
Traditional straight tubing and assembled fittings can limit routing flexibility and add unnecessary joints, labor, and potential leak points. Mercury Plastics uses advanced forming and fabrication techniques to shape thermoplastic tubing into application-specific forms that route efficiently through tight or confined spaces.
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Formed tubing integrates bends and transitions directly into the part, eliminating cuts, joints, and many conventional fittings while enabling cleaner designs, simpler assembly, and improved system reliability.
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With forming and fabrication, we can:
- Route tubing through tight spaces with integrated bends and transitions
- Eliminate cuts, joints, and many traditional fittings
- Reduce stress and side-loading on connections and interfaces
- Create continuous fluid or air paths that minimize leak points
- Produce one-piece systems when paired with overmolded end connections
- Support poka-yoke solutions through color-coded tubing
In addition to providing design input, Mercury Plastics engineers design and build all tooling in-house, enabling optimal material selection, precise dimensional control, and tooling solutions matched to production volumes. This integrated approach delivers more manufacturable parts with lower total system cost.
Comprehensive Fabrication Capabilities
Extending Beyond Forming to Finished, Production-Ready Components
In addition to forming, Mercury Plastics offers a full range of fabrication services to deliver finished, production-ready components:
- Assembly
- Belling
- Addition of fittings and grommets
- Pad printing and laserjet marking
- Pressure decay and flow testing
- Precision cutting
- Punching and drilling
By combining forming with fabrication services, Mercury Plastics helps customers reduce complexity, streamline assembly, and improve overall system reliability.
Core Thermoplastic Processes Under One Roof
Mercury Plastics is unique in offering all plastics and e-beam capabilities under one roof: extrusion, Air-Core® molding, forming, fabrication, injection overmolding, and irradiation crosslinking. This eliminates fragmentation and enables faster iterations from concept to finished part.
Our engineering teams frequently combine extrusion with:
Air-Core® Molding
Beginning with a tailored profile or tube, Air-Core® can introduce molded features at precise locations along the length.
Extrusion
Precision extrusion enables tight tolerances, consistent performance, and material flexibility across complex, high-volume applications
Injection Overmolding
Overmolding creates leak-free joints and end details without adhesives, clamps, or heat sealing.
Electron Beam Crosslinking
Crosslinking enhances thermal, chemical, and mechanical performance of polyethylene, TPE, and other compatible materials, extending product life and improving structural integrity.
Engineering Support from Start to Finish
Our engineers collaborate with you early—using SolidWorks®, Moldflow®, FEA, prototyping, and our in-house machine shop—to optimize manufacturability, reduce cost, and achieve performance targets.
Why Choose Mercury Plastics?
A Partner for Complex, Multi-Step Thermoplastic Programs
Deep Engineering Expertise
Decades of experience across molding, extrusion, forming, and crosslinking—plus advanced modeling and analysis tools—help us solve design challenges early in the process.
High-Performance Manufacturing
Forming and fabrication are integrated with our full suite of manufacturing capabilities, providing a seamless path from concept to finished, production-ready components.
Continuous Innovation
From advanced forming techniques to complex routed shapes and fabrication services, Mercury Plastics continually develops engineering solutions that reduce cost, simplify assembly, and improve system reliability.
ISO-Certified Quality
Our ISO 9001:2015 registered Quality Management System reflects the rigorous controls and testing customers expect in critical applications.
Thermoplastics Resources & Education
Get Started with Mercury Plastics
Discover how Mercury Plastics can help you improve product performance, reduce costs, and accelerate time-to-market.