The Vacuum Forming Process
In vacuum forming, a plastic sheet is heated until it becomes pliable, then it is sucked onto a mold using vacuum to take its shape. Discover our 5-step methodology.
Tooling & Preparation
We start by creating a precision aluminum or epoxy mold based on CAD designs. The mold is engineered with proper draft angles and cooling channels to ensure a perfect release.
Heating the Sheet
A sheet of thermoplastic is clamped and shuttled into the heating oven. Quartz heaters precisely raise the temperature of the plastic until it reaches its optimal pliability.
Pre-blow (Bubble)
To prevent webbing and ensure even material distribution, compressed air is blown beneath the heated sheet, creating a large, pre-stretched bubble.
Vacuum Forming
The tool is raised into the bubble, and a high-powered vacuum instantly sucks the air out, snapping the heated plastic tightly against the contours of the mold.
Cooling & Trimming
The formed plastic cools and solidifies. It is then ejected from the mold and moved to our 5-axis CNC routers where excess material is precisely trimmed away.
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