Pressure Forming

Pressure forming is a thermoforming process similar to vacuum

forming. Except, air or liquid pressure is applied to push down on the
part in addition to the vacuum pulling down the part. Higher forming
pressures (20 to 80 psi typical) as compared to vacuum forming (14.7
psi) increase its ability to pick up fine surface details and textures.

Pre-blow and plug assist can produce parts with deeper draws (2:1
ratio).

The pressure forming process produces a part that can compete with
more costly processes (ie. injection molding).

As part size increases, so does the cost advantage over similar

processes.

Pressure Molding

# of Relati Relati
Parts Tool ve ve
Produc Construc Tool Piece Advanta Limitati Surface Part Toleran Applicati Materi
ed tion Cost Cost ges ons Finish Size ces ons als
up to Aluminu 20- 200- Cost Higher Good to Up to 24 General Compute Materia
50,000 m 40% 220% material excellent × 48 × outside r business ls best
(machine costs 18" deep dimensi machine suited:
 d and (SMC) on: ± housings ABS
fabricated Lead Best of Limited 5% first Acrylic
) time Part thermo- by sheet inch + . Zenith
complex processes size 002 video Polycar
High ity: at picking inch/inc camara b
forming attachme up details Commer h case
pressure nt cial addition
s (20-80 features, Draft: sheet: . al Cabinetry
psi) internal 1/side + 003-.50"
ribs 1/.001" thick
Combini texture
ng Edge depth
pressure appearan
forming ce and
with pre- secondar
blow and y
plug applicati
assist ons
produces
parts Draw
compati depth-
ble with 1:1 ratio
inj. used as a
molding quidelin
e
1,000- Aluminu 20- 160% Small Same as Same -  
50,000 m (cast) 40% radii above except
possibe porosity
of tool
Sharper can cause
surface imperfect
definitio ions
n than
with vac
or blow
molding

Molded
in inserts
possible

Undercu
ts
possible
20,000 Spray 30%   Same as Same as Good  
metal above above
Texture is
added to
master
pattern
5,000 Epoxy 10%   Same as Same as Fair  
 above above

Lead Cycle
time time

Avoid
small
details
2,500 Wood 5%   Same as Same as Fair  
above above

Easy to Cycle
modify time
tool
Avoid
small
details