What is Vacuum Forming?

Vacuum forming is a manufacturing process used to shape plastic sheets into various three-dimensional objects. It is a form of thermoforming in which the desired shape is produced by vacuum-forming a heated plastic sheet around a mold. The process is widely used to produce a variety of products and components, ranging from packaging materials to automotive parts and custom-made items.

The vacuum forming process typically involves the following steps:

  1. Mold Preparation: A mold is created, usually made from aluminum or wood, in the shape of the desired product. The mold serves as the template for forming the plastic sheet.
  2. Plastic Sheet Heating: A flat plastic sheet, often made of thermoplastic materials like ABS, HIPS and PETG, is clamped in place above the mold. The sheet is then heated until it becomes pliable and soft, making it easier to form.
  3. Forming the Plastic: Once the plastic sheet reaches the appropriate temperature, it is lowered onto the mold, and a vacuum is applied between the sheet and the mold. The vacuum removes the air trapped between the sheet and the mold, causing the plastic to be pressed tightly against the mold's surface, taking its shape.
  4. Cooling and Solidification: After the plastic sheet has taken the shape of the mold, it is allowed to cool and solidify, maintaining its new three-dimensional form.
  5. Trimming and Finishing: Once the plastic has cooled and hardened, any excess material is trimmed away to create the final product. Additional finishing processes like cutting, drilling, or painting may also be performed as needed.

For more information on our range of products suitable for vacuum forming, please get in touch on 01727 863138 or email sales@stephen-webster.co.uk