Common problems encountered in the cut sheet thermoforming process include thin spots, webbing, crowning and plug/pusher mark off. Syntactic foam can be used in various ways with both positive and negative tooling to alleviate these issues. Syntactic plugs result in improved material distribution leading to opportunities for down-gauging. Compared to other common plug/pusher materials such as wood and felt-covered wood, syntactic foam results in minimal plug mark-off and improved plug durability. Attached article as published in The Thermoforming Quarterly provides details.