The objective of this paper is to investigate into the development of a thin flat panel photo-bioreactor case with characteristics shapes. The thin flat panel photo-bioreactor case was designed to be manufactured from a plastic thermoforming process. A proper design with a relatively high rigidity was obtained through the structural analyses for different designs of the photo-bioreactor case. The thermoforming analyses were performed. From the results of the thermoforming analyses, a proper forming condition and the formability of the designed plastic photo-bioreactor case were estimated. The thermoforming moulds for the flat panel photobioreactor cases were manufactured. The thermoforming experiments were performed to examine the manufacturability of the designed flat panel photo-bioreactor cases. From the results of the thermoforming experiments, it was shown that thin flat panel photo-bioreactor cases with characteristic shapes can be manufactured from the designed thermoforming mould and process.