Thermoforming

Vacuum forming
Vacuum forming is a process by which a plastic sheet is heated and
shaped into a product. The two basic forming methods are drape
forming (male or positive mold) and forming into a cavity (female
mold). The sheet material is heated and lowered over the mold. Cooling
of the part is done by contact or direct water cooling.

Straight forming into a female mold allows parts with vertical walls to
shrink and be removed without stressing the part.

With drape forming, the part cools and shrinks around the male mold
causing removal problems. Draft angles and material shrinkage need to
be considered.

Plug assist can produce parts with deeper draws (2:1 ratio)

Vacuum Forming
Rel Rel
ativ ativ
e e
# of Too Piec
Parts Tool l e Surfac
Prod Constr Cos Cos Adva Limit e Part Toler Applic Materi
uced uction t t ntages ations Finish Size ances ations als
50,00 Steel 60% 200 Cost Part Typical Area: Gener Large, Materia
0+ % Compl parts 1 sq. al: shallo ls best
High exity - have in-300 ± 5% w, thin suited:
produc minim texture sq. ft. of walled ABS
 um (coarse dimen parts Acrylic
tion feature ) to Limite sion with Polycar
rates s for cover d by genero b
possib attach imperf sheet Wall: us radii
le ment ections size ± Other
20% Refrid Materia
Can Draw Draft: Comm of gerator ls:
add depth - 1/2 ercial nomin linings Cellulo
reinfor 1:1 min. sheet: al sics
cing ratio plus . Consu Flouroc
fibers used add 003-.5 mer arbons
as 1/.001" 0"thic packag Nylon
guideli texture k ing Polyeth
ne depth ylene
Boat Polystr
Definit hulls yene
ion PVC
Polysul
Bus fone
Trimm and
ing aircraft
require interior
d parts

Non-
unifor
m wall
thickn
ess

Dimen
sional
accura
cy
50,00 Alumin 40%   Tool Same Same  
0 um Durabi as as
lity above above

Tool
life
25,00 Spray 30%   Cost Same   Gener
0 metal as ally
Lead above used
time on
large
Excell parts
ent such
detail as
door
panels
5,000 Epoxy 10%   Cost Same Far-  
as less
 above detail
Lead
time Cycle
time

Avoid
small
details
1,000 Wood 5%   Cost Same Far-  
as less
Easy above detail
to
modif Cycle
y time

Avoid
small
details