The thermoforming process largely involves reciprocating mechanical motions both in the forming process and in the trimming of formed articles using sharp instruments, which provide many opportunities for accidents. Therefore, it is important to have awareness of safety and safe working conditions. Proper training in handling of thermoforming equipment should be provided to employees of corporations directly involved in thermoforming. In addition, warning signs, built-in-safety measures and recurring hazard evaluations help in mitigating, minimizing and sometimes eliminating the risk of an accident. Major accidents with thermoforming machines are caused primarily by inadequate safeguarding, safeguarding that has been removed and safeguarding that has been overridden. This chapter provides insight on the causes of accidents in the thermoforming industry and different ways to prevent these accidents. In addition, this chapter also covers recycling and its economics, and the environmental impact of scrap.