Yes, there are several options; however, they are more expensive and have a longer lead time to obtain.

Models printed with resin can withstand the heat and pressure of vacuum forming; however, much will depend on the shape and dimensions of the model. Even with resin, you will only get a few parts before the model deteriorates. Depending on the shape, dimensions, and number of parts desired, we will make a production mold (or numerous molds) using the 3D-printed model and vacuum form using the production mold(s).

Generally no; plastic stretches while forming causing uneven thickness. There are methods of minimizing plastic stretch to better maintain thickness, but uniform thickness is very difficult to achieve.

Yes, but on polyurethane foam, not on EPS foams. Lighter the density foams would require a skin and would only produce a handful of parts- usually less than 10. If more parts are needed, a higher density foam must be used or a production mold made from the foam master.

Depending on the quantity, quality, and dimensions, they can be as fast as same-day.

The readily-available plastics are clear, white, and black. Plastic color can only be customized (color, pattern, etc.) if the order is large enough to meet the plastic extruder's minimums.

Generally undercuts are not allowed on vacuum forming molds because they cause the plastic to grab the mold preventing release; however, due to our expertise and machine capabilities, some undercuts are acceptable. We would need to discuss them on a per-project basis.