Pre-Made Vacuum Formed Molding Kits for Retail Window Displays
Project Overview
This project focused on the development of pre-made vacuum formed wall molding kits for a multi-location retail customer.
The molding kits were designed for window display installations and shipped directly to individual store locations, ready for fast and consistent installation.
Originally, the customer planned to purchase standard wall molding and corner pieces from Home Depot and complete all cutting, mitering, and assembly work independently in each store. After reviewing material costs, labor time, and the risk of inconsistent results, it became clear that a custom molding kit solution offered a significantly more efficient and scalable approach.Start writing here...
Design Challenge
Retail window displays demand:
Consistent appearance across all locations
Fast installation with minimal skilled labor
Clean corners without complex miter cuts
Lightweight, durable materials suitable for repeated seasonal changes
Traditional wall molding installation requires precise measuring, difficult miter cuts, and on-site adjustments—especially problematic when scaled across multiple stores.
Our Solution
Custom Vacuum Formed Molding Kits
865 Fab Lab designed and produced custom wall molding panels using vacuum forming to create repeatable, lightweight components that could be shipped flat and installed quickly.
Key elements of the solution included:
Vacuum formed decorative wall panels in multiple configurations
Pre-shaped corners eliminating the need for on-site miter cuts
Consistent profiles across every store location
Reduced material waste and labor time
The result was a ready-to-install wall molding kit system optimized for retail environments.
"We are beyond happy with 865 Fab Lab's Retail Display work, and continue to be excited to work on new projects in the future."
Materials & Manufacturing
To balance strength, weight, and cost efficiency, the project combined multiple fabrication methods:
Vacuum formed panels for shaped molding sections
XPS foam straight lengths CNC-cut for lightweight linear sections
Modular sizing to suit different window display layouts
Vacuum forming allowed us to replicate complex molding shapes at scale while maintaining tight dimensional consistency—ideal for branded retail rollouts.
Production & Distribution
Panels were produced in batches and packaged as store-ready kits, then shipped directly to each retail location. This approach eliminated:
Store-level fabrication work
Skilled labor requirements
Inconsistent results between installations
Each store received the same components, ensuring a uniform appearance across the entire retail network.
Cost & Efficiency Benefits
Compared to sourcing individual molding pieces and performing on-site assembly, the vacuum formed molding kits delivered clear advantages:
Lower total material cost
Reduced installation labor
No miter cutting or fitting errors
Faster store setup times
Improved visual consistency
For the customer, the decision became straightforward once labor, waste, and time were factored in.
Applications
While developed for retail window displays, this solution is also well suited to:
Decorative wall molding in commercial interiors
Pop-up retail displays
Cosmetics and liquor brand installations
Temporary architectural features
Event and seasonal merchandising displays
The modular nature of the kits makes them adaptable across multiple industries.
Why This Project Matters
This case study highlights how custom fabrication can outperform off-the-shelf solutions when projects scale across locations.
By combining:
Vacuum forming expertise
CNC machining
Material optimization
Display and signage industry experience
865 Fab Lab delivered a solution that reduced cost, simplified installation, and improved overall quality.
Looking for Custom Wall Molding or Display Kits?
If you’re planning a project involving custom wall molding kits, decorative wall panels, or retail display fabrication, our team can design and manufacture a solution tailored to your rollout needs.
Contact 865 Fab Lab to discuss your project requirements.