Designed and built an aluminum-filled epoxy thermoforming tool for production use on Nasco’s in-house thermoforming machine.

The tool was developed from patterns I created using my original manikin prototypes, ensuring the formed parts accurately reflected the intended product geometry. I cast the tool in aluminum-filled epoxy to provide the durability and thermal performance needed for repeated forming, then drilled the vacuum holes, bent and installed the water-cooling lines, and sealed the vacuum box to support consistent part production.

The project required hands-on execution across pattern making, tooling design, casting, cooling integration, vacuum performance, and production readiness. The final tool enabled Nasco to manufacture formed components internally, improving control over quality, fit, and iteration speed during product development and production.