Introduction
With over 15 years of experience in manufacturing, Micah Chaban has seen the industry evolve firsthand. As a founder and VP of Sales and Marketing at RapidMade, he has built a company that specializes in cutting-edge manufacturing techniques, including thermoforming, CNC machining, and 3D printing. His expertise bridges the gap between traditional and advanced manufacturing, helping businesses optimize their production processes with cost-effective and scalable solutions.
In this interview, Micah shares his insights on the future of manufacturing, the role of thermoforming in modern production, and how RapidMade is shaping the industry.
What inspired you to start RapidMade, and what gap in the manufacturing industry were you aiming to fill?
Fifteen years ago right after the Great Financial Crisis, we saw a disconnect between what customers needed and what traditional manufacturers were offering. The industry was set in its ways—long lead times, high minimum orders, and a reluctance to adopt new technologies. Supply chains had been shipped overseas and the manufacturing supply base was hollowed out. Companies needed more flexibility, faster turnaround times, and a manufacturing partner that could pivot as their needs evolved. There was a serious opportunity to fill the gap for American made manufacturing before the conversations about “re-shoring” became mainstream.
That's where RapidMade comes in. We built the company on the idea that manufacturing should be responsive, adaptable, and efficient. By leveraging thermoforming, CNC machining, and 3D printing, we help businesses get high-quality parts quickly—without the high costs of traditional tooling.
Thermoforming is a major focus for RapidMade. What makes it such a valuable manufacturing process?
Thermoforming is one of the most underrated manufacturing processes out there. It's fast, cost-effective, and perfect for medium to large-sized parts that don't require the complexity of injection molding. A lot of people assume injection molding is the best option, but when you factor in tooling costs and lead times, thermoforming often makes more sense—especially for short- to medium-production runs.
Another advantage is design flexibility. With pressure forming, for example, we can create highly detailed textures and sharp edges that rival injection molding. And with advances in 3D-printed tooling, we're able to shorten lead times even further.
How do you see the role of automation shaping the future of manufacturing?
Automation is no longer a luxury—it's a necessity. In thermoforming, major improvements in quality and efficiency stem from advanced process monitoring and automation. Automated systems now make real-time adjustments to forming temperatures and pressure settings, reducing defects and material waste.
On the CNC side, multi-axis machining combined with robotics can enable near-zero manual finishing on production runs.
We are experimenting with robots doing finishing operations for us like sanding molds and end use parts. We also are looking into robotics to manage our paint shop to save on labor and improve quality and consistency.
The bottom line? The future of manufacturing is about doing more with less—less material waste, less labor, and less downtime. It is essential to cut down on labor costs in order to bring this work back to the USA. Companies that embrace automation will lead the industry in the next decade.
What innovations in thermoforming are you most excited about?
3D-printed tooling is a game-changer. Traditionally, thermoforming molds were made from cast or machined aluminum, which could take weeks to produce. Now, we're using high-temperature 3D-printed molds that can be created in a fraction of the time. This means we can go from design to production in days instead of weeks.
Another exciting development is thermoformable carbon fiber. It combines the strength and lightweight properties of carbon fiber with the flexibility of thermoforming. This is opening up new applications in aerospace, robotics, and automotive manufacturing, where weight reduction is critical.
Sustainability is another area where we're seeing big advancements. More recyclable and biodegradable thermoplastics are entering the market, which is great for companies looking to reduce their environmental footprint. I am following some new biodegradable plastics which could usher in a whole new era of sustainability for our industry.
What are some common misconceptions about thermoforming, and how do you address them?
The biggest misconception is that thermoforming is just for basic plastic trays and packaging. People don't realize how advanced the process has become. Pressure forming allows us to create detailed textures, sharp edges, and undercuts that look nearly identical to injection-molded parts.
Another myth is that thermoforming is only for low-volume production. While it's true that it excels in short to medium runs, high-volume thermoforming is very much a reality—especially with automated trimming and robotic loading.
At RapidMade, we take the time to educate our customers on what thermoforming can actually do. Once they see the quality and cost savings, they quickly realize it's a serious contender for their manufacturing needs.
RapidMade is known for offering multiple manufacturing processes, including CNC machining and 3D printing. How do you help customers choose the right one?
It all comes down to the project's needs—cost, lead time, and part complexity. If a customer needs thousands of small, highly detailed parts, 3D printing via MJF might be the way to go. But if they need larger parts from a single surface, thermoforming is a better fit.
CNC machining is ideal for high-precision parts that require tight tolerances, while 3D printing is great for rapid prototyping or low-volume production of complex geometries.
We guide our customers through the decision-making process by weighing the pros and cons of each method. Our goal isn't to sell a specific process—it's to find the most efficient and cost-effective solution for their specific needs. If a customer is best suited with a service we don't offer like high volume injection molding or sheet metal fabrication we will recommend those and point them in the right direction for another vendor.
Where do you see the manufacturing industry headed in the next 5–10 years?
Three major trends are shaping the future of manufacturing: automation, data-driven efficiency, and onshoring.
Automation is increasing productivity, but skilled labor remains essential. Robotics and smart systems will streamline repetitive tasks, yet experienced workers will still handle complex processes, precision work, and quality control. In my opinion there will always be a shortage of qualified 5 axis CNC machinists.
Data-driven efficiency is transforming inventory management, production planning, and process optimization. Manufacturers leveraging real-time analytics will reduce downtime, cut waste, and improve output without unnecessary costs. There is a lot of hype around AI but its only as good as the data you feed it.
Onshoring is gaining traction as companies seek supply chain resilience and faster turnaround times. Companies are tired of having their product stuck in customers or on a boat off shore. They are tired of fretting about tariffs. Advances in robotics and lean manufacturing are making localized production more competitive, especially for high-mix, low-volume operations.
Customization will continue to grow, but skilled labor will remain indispensable, especially for boutique and specialized manufacturing. The future is about balancing automation with expertise, maximizing efficiency without sacrificing quality.
For companies looking to improve their manufacturing processes, what advice would you give them?
Don't just follow the status quo. Take the time to explore new manufacturing methods and materials. Many companies stick with what they know—whether it's injection molding, machining, or overseas production—without realizing there are better, more cost-effective alternatives.
The number one question I always ask myself is how can I add more products, services and materials without making additional equipment investments. Maybe there is a new composite material for thermoforming or a new high performance coating I can offer through my paint shop - anything that taps into a new market where I might not be competing. Always listen to the customers because they will drive the demand.
Work with a manufacturing partner who understands multiple processes and can help you find the best fit. Whether it's thermoforming, 3D printing, or CNC machining, the right approach can save you time, money, and headaches.
And finally—think long-term. Manufacturing is evolving fast. The decisions you make today should set you up for success five, ten, or even twenty years down the line.
At RapidMade, we specialize in helping businesses streamline their manufacturing with cutting-edge processes like thermoforming, CNC machining, and 3D printing. Whether you need high-quality prototypes, low-cost production solutions, or expert engineering guidance on the best manufacturing method for your needs, our team is here to help.
Visit RapidMade.com to learn more, or contact us today to discuss how we can bring your designs to life with precision, speed, and efficiency.
