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Your plant's expertise.
Available at 2am.

The most experienced people on your floor will retire in the next three to five years.

We capture what they know and make it available to everyone — any shift, any site, any question.

This is thermoform.ai

Request a demo

Black background

Your plant's expertise. Available at 2am.

The most experienced people on your floor will retire in the next three to five years. thermoform.ai captures what they know and makes it available to everyone — any shift, any site, any question.

Request a demo

Black background

Your plant's expertise.
Available at 2am.

The most experienced people on your floor will retire in the next three to five years.

We capture what they know and make it available to everyone — any shift, any site, any question.

This is thermoform.ai

Request a demo

The Challenge

3 Problems. 1 Platform.

Tribal Knowledge

Tribal Knowledge

80% of process-critical expertise exists only in operators' heads. The technician who knows how your specific resin behaves on humid days. Who can hear a servo motor starting to fail before any sensor flags it. Who built your best recipes over years of trial and error. That knowledge has never been written down. And it retires with them.

80% of process-critical expertise exists only in operators' heads. The technician who knows how your specific resin behaves on humid days. Who can hear a servo motor starting to fail before any sensor flags it. Who built your best recipes over years of trial and error. That knowledge has never been written down. And it retires with them.

The Retrieval Problem

The Retrieval Problem

Your documentation exists. Finding it at 2am is another matter. A second-shift operator dealing with a press out of parallel doesn't have time to search a shared drive. Three versions of the troubleshooting guide with no dates. A binder three feet away that doesn't match his machine configuration. So he improvises. And the plant re-learns a lesson it already paid for.

Your documentation exists. Finding it at 2am is another matter. A second-shift operator dealing with a press out of parallel doesn't have time to search a shared drive. Three versions of the troubleshooting guide with no dates. A binder three feet away that doesn't match his machine configuration. So he improvises. And the plant re-learns a lesson it already paid for.

The Data Gap

The Data Gap

Your historian has years of sensor data. Most of it has never been read.

Manufacturers have spent millions instrumenting production lines. SQL servers stuffed with terabytes of information spanning years of operations. The problem is not data availability. The gap between raw numbers and a decision a floor manager can act on remains, for most plants, uncrossed.

Your historian has years of sensor data. Most of it has never been read.

Manufacturers have spent millions instrumenting production lines. SQL servers stuffed with terabytes of information spanning years of operations. The problem is not data availability. The gap between raw numbers and a decision a floor manager can act on remains, for most plants, uncrossed.

The Solution

A domain-specific AI built for thermoforming. Not a generic chatbot.

thermoform.ai combines CognitionWorks' Sprocket AI platform with Mark Strachan's 25+ years of Global Thermoform Training Institute (GTTI) materials: thousands of documents, troubleshooting guides, process tools, and training content specific to thermoforming.

Ask it a question in plain English. Get a precise answer with a citation back to the source material.

ChatGPT can handle general manufacturing questions. It will not troubleshoot film gauge variation in your specific forming application. thermoform.ai will.

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Machines

From large-bed US to high-speed tilt mold European machines. And everything in between.

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Materials

If you can extrude it, you can thermoform it. We've tried them all.

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Molds

Steel-rule die. Matched metal. Forged knives. Progressive dies. What else you got?

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Molds

Steel-rule die. Matched metal. Forged knives. Progressive dies. What else you got?

Features

What it Does

Everything your best operator knows.
Plus everything they forgot to write down.

Ask questions in plain English

A younger technician doesn't want to guess what a document is titled. He wants to say: "I'm getting flow lines on a PET tray" — and get a response that points to the right procedure or training module. That's what the platform returns. With a citation to the source.

Process Troubleshooting

Hundreds of scenarios. Specific to thermoforming. Answers grounded in the GTTI library plus your own plant documentation — not generic manufacturing advice.

Tribal Knowledge Capture

Upload your SOPs, maintenance logs, recipes, even short videos. A thirty-second voice note from a technician explaining how they diagnosed a servo fault contains more actionable information than three pages of procedure written after the fact. The platform synthesizes recordings into searchable content. Your plant's process history becomes queryable.

Integrations*

Connect to SQL databases, IQMS, network drives, and ERP systems. Production data becomes decision-ready. One shift manager verified a scrap rate increase, ran a Pareto analysis, and isolated root causes in under thirty seconds. *Only with full Sprocket upgrade

24/7 Availability

Cloud-based. No installation. Any device with a browser. Night shift challenges don't wait for day shift expertise. Weekend quality issues can't pause until Monday morning. The platform is always on.

Multilingual

One click. Dozens of languages. When a team shares equipment but not a first language, the cost shows up as slower troubleshooting and inconsistent setups. Multilingual support is practical, not political.

Enterprise-grade security. Your data stays yours.

The platform runs on AWS infrastructure with encryption at rest and in transit. Each company's data vault is isolated — your documentation, your chat history, your recipes are never shared with other users on the platform.

The architecture has passed security audits from Coca-Cola, Baxter International, and BDO.

No local installation required. Any device with a browser and login credentials works.

Request demo

Request demo

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Advantages

The exptertise is still there. For now.

The average experienced process technician in plastics manufacturing is in their mid-to-late fifties. The knowledge transfer mechanisms most companies have in place were designed for a world where retirements were gradual and replacements were available.

Neither of those conditions holds anymore.

A three-month pilot gives your team full access to the thermoform.ai content library plus elements of the Sprocket platform. Unlimited users.

The expertise is still there. For now.

The average experienced process technician in plastics manufacturing is in their mid-to-late fifties. The knowledge transfer mechanisms most companies have in place were designed for a world where retirements were gradual and replacements were available. Neither of those conditions holds anymore. A three-month pilot gives your team full access to the thermoform.ai content library plus the Sprocket platform. Unlimited users.

Capture tribal knowledge - before it walks out the door.

Capture tribal knowledge -
before it walks out the door.

Capture tribal knowledge - before it walks out the door.