Compression Thermoforming

Compression Thermoforming

If you are searching for "green" solutions for an upcoming project, consider Melet's natural fiber composites. Using natural fiber substrates or reclaimed Polypropylene natural fiber substrates, Melet provides eco-friendly, cost competitive, lightweight and strong solutions which are excellent alternatives to plastic substrates.

Natural fibers are annual crops grown in many countries around the world. Fiber stocks are harvested and shipped to processing plants were they are converted into useable raw materials. The natural fiber is blended with a small amount of plastic and processed into non-woven mats of natural fiber substrate.


  • Natural fiber mats are molded in a unique and innovative one-shot thermoforming process.

  • The molded product is suitable for any interior application in a variety of industries including automotive, construction, forestry, agriculture and consumer goods.

Cover Materials

Melet offers a variety of cover materials that can be molded or bonded to the Natural Fiber Substrate to meet the customer's specific needs.


  • Carpet Covers are available in a wide range of colors and weights that are affordable, durable and dress up any interior.

  • Vinyl Covers are available in a wide range of colors and are tough, durable, and easy to clean.

  • PET Covers can be used for "under the hood" applications. They are oil resistant and can be cleaned with a pressure washer.

Supplementary Materials


  • Cotton Shoddy is used in noise reduction (sound absorption) and thermal insulation
    programs.

  • Melt Blown Polypropylene is used in noise reduction (sound absorption) and thermal insulation programs.

  • Open Cell Foams are used in many noise reduction programs. They are available in numerous densities and colors.

  • Closed Cell Foams do not absorb water and can be used in high temperature applications. They are available in numerous densities and colors.

Please Contact us to find out what material is right for you.

Compression thermoforming is completed through a four step manufacturing process:

1. Loading

Using automation and skilled workers, we prepare the natural fiber substrate and cover stock materials for molding.

2. Molding

After pre-heating, the raw material is transferred into the mold and formed into the desired shape.


3. Trimming:

After molding, a dual-head, six axis waterjet cutting center precisely trims the finished components.


4. Assembly:

Once complete, mating components can be assembled so that your product arrives fully assembled.



With cycle times of one to two minutes in conjunction with our automated machinery, we can meet the volume demands of any challenge.