Once your vacuum-formed items have been designed, the tool manufactured, and the items formed in the factory, there are several ways to finish them to achieve the desired final result.
For example, some packaging items may require euro-slots for display on shop racking systems, or formings might need cable holes or other features added to complete them. Each finishing process has its pros and cons, as well as cost implications. Below is an overview of some of the many finishing options, along with their advantages and disadvantages.
Hand Finishing
There are two methods for hand-finishing parts: trimming by hand or using a band saw.
For single or very small production runs in softer or less brittle plastics, items can be scored, and the excess material snapped off. Thinner and softer materials can simply be cut with a hand knife.
If the production quantity is slightly larger and a high level of finishing precision isn’t required, a table band saw can be used. A jig or fence can be applied to ensure consistency in cutting. However, like hand trimming, this method isn’t suitable for large production runs.
Guillotining
Guillotining is a simple and clean method of removing vacuum-formed parts from the material sheet. It is ideal for low-production runs requiring straight or basic cuts.
However, this method is not suitable for more complex jobs or those requiring intricate cuts, such as radius corners, which can be too time-consuming or complicated for guillotining.
Drilling
Holes can generally be drilled manually through many vacuum-formed parts. Jigs can be used to ensure consistent hole placement across the job. However, due to its manual nature, drilling is best suited to larger pieces or smaller production runs.
Roller Cutting
Roller cutting is a fast and efficient method for cutting vacuum-formed items from the original material sheet. It uses a cutting guide template, which is pressed down onto the item by a set of rollers inside the machine, resulting in a part cut to the desired specifications. Vertical features such as euro-slots or cable holes can be cut at the same time.
This method is excellent for larger items where precision within tenths of a millimetre is not essential. However, minor misalignments can occur as the item moves through the cutting machine. It’s also not possible to make side cuts or horizontal holes, as the blade operates vertically.
Vertical Press Cutting
Vertical press cutting is an alternative to roller cutting, offering greater detail and accuracy for parts requiring a more refined finish.
It is similar to roller cutting but provides a much higher quality of finish since the part remains rigid in a frame. This process is commonly used to punch small finished items from a plastic sheet, rather than adding detailed cuts to the product.
Press cutting tools are generally more expensive than roller cutter tools. Like roller cutting, it does not allow for side cuts or additional features to be added to a part.
CNC Trimming
CNC trimming is the most accurate method for cutting and adding features like holes, with our machines capable of trimming within 0.1mm accuracy.
CNC is ideal for more complex jobs requiring intricate detailing. CAD data is typically used to create the cuts, although in some cases, hand-finished parts can be adapted to generate the NC code.
This process, using state-of-the-art machinery, can be more expensive but is an excellent choice when hand finishing is insufficient for the complexity of the job.
If you would like to learn more about the vacuum forming finishing processes we use at our production facility in Leeds, or how to best finish your project, please feel free to call or email us.
Back to News