Home > Products > Custom Products > Thermoformed Packaging > Thermoformed Packaging Processes Thermoformed Packaging Processes Thermforming is an effective process to manufacture custom protective dunnage. The thermoforming process, also called vacuum forming, involves heating a plastic sheet, forming it to a mold and cooling. The thickness of the sheet and material type determines the finished packaging's attributes, from impact resistance to rigidity. ORBIS offers thin and thick gauge thermorming for its dunnage line. This dunnage can be inserted into totes or used as stand-alone packaging.