Custom Plastic Fabrication Services
Expert plastic fabrication services including plastic welding, thermoforming, bending, cutting, and mechanical assembly for industrial tanks, enclosures, machine guards, and custom components. ISO 9001:2015 certified quality systems serving Aerospace, Defense, Chemical Processing, and Manufacturing industries nationwide.
ISO 9001:2015 Certified Fabrication for Mission-Critical Industries
Plastic fabrication transforms thermoplastic sheet, rod, and tube materials into custom industrial components through plastic welding, thermoforming, CNC cutting, and mechanical assembly. Lehigh Valley Plastics provides ISO 9001:2015 certified fabrication services for chemical storage tanks, process equipment, machine guards, cleanroom panels, ducting systems, and custom enclosures serving Chemical Processing, Pharmaceutical, Semiconductor, Food & Beverage, and Industrial Manufacturing applications requiring corrosion resistance, leak-free construction, and regulatory compliance documentation.
Why ISO 9001:2015 Certification Matters for Fabricated Components
ISO 9001:2015 certification ensures fabricated plastic assemblies meet dimensional specifications, material requirements, and welding quality standards through documented procedures, inspection protocols, and continuous improvement processes. For procurement officers specifying process equipment and containment systems, ISO 9001:2015 certification provides:
- Welding Procedure Qualification: Documented welding parameters, operator certification, and weld quality inspection protocols
- Material Traceability: Mill certifications linking fabricated assemblies to certified raw material lots
- Dimensional Verification: In-process measurements and final inspection ensuring assemblies meet design specifications
- Leak Testing Documentation: Hydrostatic pressure testing, vacuum testing, or visual inspection records for containment applications
- Process Control Plans: Work instructions, quality checkpoints, and acceptance criteria documented for repeatability
- Supplier Management: Qualified material suppliers providing certifications for FDA, NSF, or chemical resistance requirements
Fabrication Quality Documentation
Every fabricated assembly ships with comprehensive documentation supporting installation, regulatory compliance, and quality system requirements:
Material Certificates of Compliance: Mill test reports documenting polymer composition, chemical resistance properties, FDA compliance status, and flame spread ratings for building code compliance.
Fabrication Assembly Drawings: As-built documentation showing weld locations, reinforcement details, fitting specifications, and dimensional verification for installation coordination.
Quality Inspection Records: Visual weld inspection reports, leak test results, dimensional measurements, and material verification documentation for quality system audits and regulatory submissions.
National Plastic Fabrication Services: From Prototyping to Full Production
Lehigh Valley Plastics provides national plastic fabrication services for prototype development through production manufacturing. Our experienced fabrication team combines traditional thermoplastic welding expertise with modern CNC cutting and forming equipment to deliver custom assemblies meeting exact specifications.
Climate-controlled fabrication shop, certified welding procedures, and ISO 9001:2015 quality systems ensure consistent weld quality and dimensional accuracy for chemical processing, pharmaceutical, and industrial applications requiring leak-free construction and regulatory compliance.
Request Fabrication Quote →Thermoplastic Materials for Custom Fabrication
Material selection for fabricated assemblies balances chemical resistance, structural requirements, weldability, temperature limits, and regulatory compliance. Lehigh Valley Plastics provides material expertise ensuring optimal performance for chemical processing, food & beverage, pharmaceutical, and industrial applications.
Polypropylene (PP)
Chemical Resistance: Excellent (acids, bases, solvents)
Max Temperature: 180°F continuous / 200°F intermittent
Weldability: Excellent (all welding methods)
Fabrication Applications:
Chemical storage tanks, acid/caustic process equipment, laboratory fume hoods, electroplating tanks, and scrubber systems. FDA-compliant grades available for food contact and pharmaceutical processing.
Key Properties:
- Broad chemical resistance across pH spectrum
- Excellent stress crack resistance
- FDA 21 CFR 177.1520 compliant grades
- Cost-effective for large fabrications
PVC & CPVC
Chemical Resistance: Very Good (acids, chlorinated compounds)
Max Temperature: PVC 140°F / CPVC 200°F
Weldability: Excellent (extrusion, hot gas, solvent cement)
Fabrication Applications:
Acid exhaust ducting, chemical tanks, plating equipment, cleanroom panels, and industrial ventilation systems. CPVC provides elevated temperature capability for hot chemical applications.
Key Properties:
- Excellent acid resistance (HCl, H₂SO₄)
- Self-extinguishing flame characteristics
- NSF-61 certified for potable water contact
- Wide availability and economical pricing
HDPE (High-Density Polyethylene)
Chemical Resistance: Excellent (most chemicals except oxidizers)
Max Temperature: 180°F continuous use
Weldability: Excellent (extrusion, hot gas, butt fusion)
Fabrication Applications:
Chemical storage tanks, secondary containment, material handling chutes, wear strips, and corrosion-resistant process equipment. Natural (translucent) and UV-stabilized black grades available.
Key Properties:
- Exceptional stress crack resistance
- Low moisture absorption (0.01%)
- FDA 21 CFR 177.1520 food contact compliance
- Outstanding impact strength at low temperatures
PVDF (Polyvinylidene Fluoride)
Chemical Resistance: Outstanding (ultra-pure applications)
Max Temperature: 280°F continuous use
Weldability: Good (extrusion, hot gas, specialized techniques)
Fabrication Applications:
Semiconductor wet benches, ultra-pure chemical handling, pharmaceutical processing equipment, and high-temperature acid/solvent systems. Premium material for demanding chemical environments.
Key Properties:
- Broadest chemical resistance of thermoplastics
- Ultra-low extractables for high-purity systems
- Excellent UV and weathering resistance
- High mechanical strength retention at elevated temperatures
ABS Plastic
Chemical Resistance: Good (mild chemicals, aqueous solutions)
Max Temperature: 180°F continuous use
Weldability: Very Good (solvent cement, ultrasonic, hot gas)
Fabrication Applications:
Equipment housings, protective covers, machine guards, vacuum forming tooling, and consumer product prototypes. Excellent surface finish and aesthetic appeal.
Key Properties:
- Superior impact resistance at room temperature
- Excellent dimensional stability and rigidity
- Smooth surface finish ideal for painting
- Cost-effective for non-chemical applications
Polycarbonate
Chemical Resistance: Moderate (limited chemical exposure)
Max Temperature: 240°F continuous use
Weldability: Fair (ultrasonic, adhesive bonding preferred)
Fabrication Applications:
Machine guard windows, safety shields, protective enclosures, skylights, and impact-resistant barriers. Optical clarity and extreme toughness for safety applications.
Key Properties:
- Exceptional impact resistance (ANSI Z87.1 rated)
- Optical clarity for operator visibility
- Excellent heat resistance among transparent plastics
- UV-resistant grades for outdoor applications
Plastic Fabrication for Mission-Critical Industries
Chemical Processing & Industrial Manufacturing
Applications: Chemical storage tanks, acid/caustic process equipment, scrubber systems, fume extraction ducting, secondary containment, and corrosion-resistant process piping.
Case Study: Railcar Wear Pad Fabrication
Fabricated UHMW plastic and Nylatron (oil-filled nylon) wear pads for heavy-load railcar applications. Custom-sized pads machined and fabricated to customer specifications provide self-lubricating surfaces, reduce metal-on-metal contact, eliminate lubrication requirements, and extend service intervals in harsh rail transportation environments with extreme shock loading and temperature variations.
Material Requirements:
- Chemical resistance verification through immersion testing
- Structural analysis for unsupported tank dimensions
- Thermal expansion accommodation in piping systems
- Welding procedure qualification for critical joints
Pharmaceutical & Biotech Manufacturing
Applications: Process tanks for biopharmaceutical manufacturing, clean-in-place (CIP) systems, sterile fluid handling equipment, and pharmaceutical grade storage vessels.
Case Study: Biotech PPSU Processing Equipment
Fabricated polyphenylsulfone (PPSU) components for high-temperature bioreactor systems requiring repeated steam sterilization cycles. PPSU material selection provides compatibility with 270°F autoclave sterilization, gamma radiation exposure, aggressive cleaning agents (sodium hydroxide, bleach solutions), and USP Class VI biocompatibility for direct process contact in pharmaceutical manufacturing cleanroom environments.
Compliance Requirements:
- USP Class VI material certifications and biocompatibility data
- FDA 21 CFR compliance documentation for process contact
- Smooth, crevice-free welds preventing bacterial harboring
- Material extractables testing for ultra-pure applications
Food & Beverage Processing
Applications: Food-grade storage tanks, process equipment, wash-down enclosures, conveyor components, and sanitary fluid handling systems.
Food-Grade Materials:
FDA-compliant polypropylene, HDPE, and UHMW plastic materials meeting FDA 21 CFR 177.1520 requirements for direct food contact. Smooth, non-porous surfaces resist bacterial growth and withstand repeated cleaning with sanitizing solutions and high-pressure wash-down protocols.
Sanitary Design Features:
- Smooth, crevice-free welded joints meeting 3-A sanitary standards
- Self-draining configurations preventing bacterial growth
- Radius corners and filleted edges for cleaning accessibility
- Chemical resistance to sanitizers, acids, and caustic cleaners
Custom Fabrication Process: Engineering Through Installation
Engineering Consultation
Submit specifications, sketches, or existing equipment photos. Our engineering team reviews application requirements, material compatibility, structural considerations, and fabrication feasibility. Design recommendations optimize cost, performance, and manufacturability.
Design & Fabrication Drawings
CAD drawings developed showing dimensions, weld locations, reinforcement details, and fitting specifications. Customer review and approval ensures design intent before material procurement and fabrication begins. Revisions incorporated before production commitment.
Material Procurement & Fabrication
Certified thermoplastic materials procured with mill certifications documenting chemical composition and compliance. Experienced fabricators construct assemblies following work instructions, welding procedures, and quality checkpoints. In-process inspection verifies dimensional accuracy.
Quality Inspection & Delivery
Final dimensional verification, visual weld inspection, and leak testing (when specified). Material certifications, fabrication drawings, inspection reports, and test documentation packaged with shipment. Installation support and technical assistance available.
Fabrication Material Comparisons: Choosing the Right Plastic
Polypropylene VS PVC
When to Choose Polypropylene:
Polypropylene provides broader chemical resistance including strong oxidizers, higher operating temperatures (180°F vs 140°F), and superior stress crack resistance. Preferred for caustic solutions, concentrated acids, and applications requiring FDA food contact compliance. Better impact strength at low temperatures.
When to Choose PVC:
PVC offers higher rigidity, lower cost, easier solvent cement bonding, and inherent flame resistance. Preferred for acid exhaust ducting, general chemical storage, and applications where dimensional stability and ease of fabrication outweigh temperature limits. CPVC variant extends temperature capability to 200°F.
| Property | Polypropylene | PVC |
|---|---|---|
| Max Temperature | 180°F | 140°F |
| Chemical Resistance | Broader spectrum | Excellent (acids) |
| Tensile Strength | 4,500 psi | 7,500 psi |
| Flame Characteristics | Burns slowly | Self-extinguishing |
HDPE VS Polypropylene
When to Choose HDPE:
HDPE provides superior stress crack resistance, better impact strength at low temperatures, and excellent abrasion resistance. Preferred for secondary containment, material handling applications, and outdoor installations requiring UV resistance. Natural (translucent) HDPE allows visual fluid level monitoring.
When to Choose Polypropylene:
Polypropylene offers higher temperature capability (180°F vs 140°F), greater rigidity, and broader chemical resistance including strong oxidizers. Better weldability and heat forming characteristics. Preferred for elevated temperature applications and chemical processes requiring structural rigidity.
| Property | HDPE | Polypropylene |
|---|---|---|
| Stress Crack Resistance | Outstanding | Excellent |
| Impact Strength (-40°F) | No break | 2.0 ft-lb/in |
| Flexural Modulus | 150,000 psi | 200,000 psi |
| Heat Deflection Temp | 180°F | 210°F |
PVDF VS Polypropylene
When to Choose PVDF:
PVDF provides the broadest chemical resistance among thermoplastics, higher temperature capability (280°F continuous), ultra-low extractables for high-purity systems, and exceptional UV/weathering resistance. Essential for semiconductor processing, pharmaceutical ultra-pure systems, and aggressive chemical environments where polypropylene degrades.
When to Choose Polypropylene:
Polypropylene offers excellent chemical resistance at significantly lower material cost (3-5x less expensive than PVDF), easier weldability, and adequate performance for most industrial chemical applications. Preferred when ultra-high purity or extreme chemical resistance isn’t required. Better availability and shorter lead times.
| Property | PVDF | Polypropylene |
|---|---|---|
| Max Temperature | 280°F | 180°F |
| Chemical Resistance | Broadest spectrum | Excellent (most chemicals) |
| Tensile Strength | 6,500 psi | 4,500 psi |
| Relative Cost | Premium | Economical |
ABS Plastic VS Polycarbonate
When to Choose ABS Plastic:
ABS provides good impact resistance at room temperature, superior surface finish, easier machining and bonding, and lower cost. Preferred for equipment housings, protective covers, and applications where transparency isn’t required and operating temperatures remain below 180°F. Better chemical resistance to alkaline solutions.
When to Choose Polycarbonate:
Polycarbonate offers exceptional impact strength across wide temperature range, optical clarity for operator visibility, higher continuous use temperature (240°F), and superior UV resistance. Essential for machine guard windows, safety shields, and transparent protective barriers requiring ANSI Z87.1 impact ratings.
| Property | ABS | Polycarbonate |
|---|---|---|
| Impact Strength (Izod) | 10-12 ft-lb/in | 16-18 ft-lb/in |
| Optical Clarity | Opaque | Transparent |
| Max Temperature | 180°F | 240°F |
| Surface Finish | Excellent | Good |
Frequently Asked Questions About Plastic Fabrication
What is the difference between plastic fabrication and plastic machining?
Plastic fabrication joins, shapes, and assembles thermoplastic sheet, pipe, and fittings through welding, thermoforming, bending, and mechanical assembly to create tanks, enclosures, and structures. Plastic machining removes material from solid stock through CNC milling and turning to create precision components. Many projects utilize both fabrication and CNC machining services for complete assemblies.
What types of plastic welding do you offer?
Lehigh Valley Plastics provides hot gas welding, extrusion welding, ultrasonic welding, hot plate welding, and spin welding. Method selection depends on material type, joint configuration, strength requirements, and production volume. Extrusion welding provides highest strength for structural joints and critical containment applications. Welding procedure qualification available for critical applications.
Can you fabricate chemical storage tanks with leak-free construction?
Yes. We fabricate custom chemical storage tanks from polypropylene, PVDF, HDPE, and PVC/CPVC using qualified welding procedures and experienced fabricators. Tanks undergo visual weld inspection and hydrostatic pressure testing (when specified). Material certifications, fabrication drawings, and test documentation provided. Secondary containment and double-wall construction available for regulatory compliance.
What is the maximum size tank or assembly you can fabricate?
Fabrication capabilities extend to approximately 20′ x 30′ x 12′ (L x W x H) for modular assemblies constructed in our facility. Larger structures fabricated through modular panel construction, field welding, and on-site assembly. Rectangular tanks commonly fabricated to 8′ x 12′ x 8′ dimensions. Cylindrical tanks to 96″ diameter with custom heights.
Do you provide ISO 9001 quality documentation for fabricated assemblies?
Yes. Lehigh Valley Plastics is ISO 9001:2015 certified. All fabricated assemblies are manufactured under documented quality procedures with material certifications, welding procedure specifications, visual inspection reports, dimensional verification records, and leak test documentation (when applicable). As-built fabrication drawings provided showing weld locations and final dimensions.
What materials can you weld and fabricate?
We fabricate polypropylene, PVC, CPVC, HDPE, PVDF, ABS plastic, polycarbonate, acrylic (PMMA), PETG, and polysulfone. Material selection based on chemical compatibility, temperature requirements, structural loads, and regulatory compliance needs. FDA-compliant and NSF-certified grades available for food contact and potable water applications.
Can you provide engineering support for custom fabrication projects?
Yes. Our engineering team provides material selection guidance, chemical compatibility verification, structural analysis for tank sizing, thermal expansion calculations, and fabrication design recommendations. CAD drawings developed for customer review before fabrication begins. Design for Manufacturability consultation optimizes cost, performance, and installation requirements.
What is your typical lead time for custom fabrication projects?
Simple assemblies and standard tank configurations typically require 2-3 weeks from approved drawings to shipment. Complex fabrications, large tanks, or specialty materials may require 4-6 weeks depending on engineering complexity and material procurement. Expedited service available for urgent requirements. Installation support and field service coordination available.
Request a Quote for Custom Plastic Fabrication Services
Contact Lehigh Valley Plastics for expert plastic fabrication including welding, thermoforming, and assembly. ISO 9001:2015 certified quality systems, experienced fabrication team, and comprehensive material expertise for chemical processing, pharmaceutical, semiconductor, and industrial manufacturing applications requiring corrosion resistance and leak-free construction.