Solving problems for thermoforming processes in the production of axisymmetric thin walled plastics is investigated in this research work. A nonlinear viscoelastic rheological model with a new strain energy function is suggested for improvement of physical properties of final product. For model validation, a quantitative relation between stress and technical parameters of plug-assist thermoforming is determined by comparison of theoretical and experimental results. This process with the proposed rheological model could be suggested for prevention from some technical defects such as wall thickness variations, physical instability during inflation-shrinkage, and warpage exhibited in the final part of a polymeric sheet thermoforming. (c) 2006 Wiley Periodicals, Inc.