We understand that not everyone is an expert in plastic production, and you may even be completely new to the industry, having never placed an order before. So, if you’d like to learn more about the vacuum forming process and how it works, here’s what you need to know…
The vacuum forming machine was first patented in the 1940s, although many major corporations had already been developing thermoforming technology for many years prior. Despite being over 70 years old, there is still no real alternative that matches vacuum forming in terms of low cost, ease of tool creation, efficiency, and production speed for low to medium runs of plastic parts. Injection moulding is comparable in some ways, but the tooling is more complex and expensive. One of the main benefits of vacuum forming is the speed at which tooling can be produced, and the cost is significantly lower than injection moulding for smaller production quantities.
Vacuum forming is a simplified version of thermoforming, where a plastic sheet is heated to an optimal temperature, allowing it to be stretched over a single-surface mould. A vacuum then removes the air, allowing the plastic to tightly conform to the mould, forming the desired shape.
This process can be used to form many types of plastic into permanent objects, from food or seed trays to building materials, and even high-tech applications in medical equipment, automotive, and aeronautical industries. The range of applications for vacuum forming is almost limitless. At the Vacform Group, we manufacture a wide variety of parts for motorcycles, garden centres, plumbing and building merchants, as well as wholesalers and retailers of all types.
Many different types of plastic can be used in the process, available in a wide range of colours, finishes, and textures. While not every design or shape is suitable for vacuum forming, it remains the most cost-effective and efficient method for processing a diverse range of plastic applications.
The step-by-step vacuum forming process:
- A vacuum forming tool or mould is designed and manufactured to the correct shape for the desired output.
- The tool is loaded into the vacuum forming machine and heated to the appropriate temperature.
- The plastic sheet is loaded into the machine and clamped into place.
- Built-in heaters warm the material to the optimal temperature for shaping, ensuring consistent wall thickness (different plastics require different temperatures depending on their make, specification, type, and thickness).
- The softened material is momentarily supported under tension by the machine’s automatic levelling device.
- The heated tool is quickly raised to meet the suspended plastic sheet.
- A vacuum is applied, sucking the plastic over the tool, forming the desired shape.
- The plastic is then cooled rapidly by air to set the shape. Releasing it while still too warm may result in misshapen parts that are ultimately unusable.
- The formed part is removed and passed on for trimming by hand, roller cutter, punching, or CNC.
Vacuum forming offers several advantages over other forming processes. As it uses low pressure, tools can be made from a variety of less expensive materials, including wood, MDF, resins, fibreglass, or metal. Prototyping time is also often shorter compared to other plastic forming methods.
The ability to produce large parts in low quantities and smaller parts in medium runs makes vacuum forming a highly economical option for manufacturing many plastic parts.
For more information on the vacuum forming process and how it could benefit your business, please contact us via telephone or email.
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