Another satisfied customer.

Family owned and operated since 1955, Du-Call Miller Plastics has thrived in the plastics industry as a trusted, customer-focused resource for custom molds and concept-oriented designs.

Specializing in plastic thermoforming and rotational molding, our past projects include: 

  • The first prototype toilet for NASA
  • A drinking water system for the Mercury Space Project
  • The external shell for the famed Battletech game
  • Custom stair and compartment components for Amtrak rail cars
  • The famed Late Night Pickle: created in bulk for Pickle Packers International and recently handed off by Jimmy Fallon"

We welcome the opportunity to assist with the development of your custom project, we invite you to reach out to us by phone or online for a free consultation and quote. We look forward to hearing from you, and ensure a prompt response.

Thermoforming or Rotational Molding: Which is right for your project?


Thermoforming is a manufacturing process during which a heated, malleable plastic sheet is shaped on or within a mold, then trimmed to create a usable product. Thin-gauge plastics are typically molded in this way for the medical, food and retail industries, producing items like: disposable cups, blister packs, cartons, trays, containers and lids. These are normally formed on roll feed continuous forming equipment from sheet below .080. Heavier Items like vehicle door and dashboard panels, refrigerator components and truck bed liners are produced through the forming of thick-gauge plastics up to .500 starting gauge. Thermoforming is often used for sample and prototype plastic parts.

We’ve included a gallery of sample Du-Call Miller thermoformed plastics below – clicking each photo will provide a larger display. Feel free to explore and to contact us with any questions:


During the rotational molding process, a plastic powder (comparable in texture to sugar) is tumbled in a heated mold to produce detailed plastic shapes. A similar procedure, rotocasting (also known as “rotacasting”), utilizes this same technique, but with self-curing resins in an unheated mold.

Used to produce anything from large chemical tanks to smaller items like doll heads and medical displays (i.e. the model teeth, hearts or other internal organs displayed on a doctor’s counter), rotational molding and rotocasting are most often utilized for low-volume, highly specialized orders.

Examples of our rotocast work can be found in the gallery below. You’re welcome to browse, then contact us for any information you may need.

Additional Services
Additional Services

Packaging & Shipping:

Our move has allowed us to expand services of warehousing, contract packaging and drop shipping for our customers.

Contact us by phone or online for a prompt, competitive response.

du-call miller plastics
serving industry since 1955

new location
704 e north st.
elburn, il 60119
p. 630.964.6020