Fabrication: Thermoforming
aka: Vacuum Forming
The Thermoforming Process

Mr. Plastics provides in-house plastics vacuum forming and thermoforming services. Vacuum forming is a simplified version of thermoforming, whereby a sheet of plastic is heated to a forming temperature, stretched onto or into a single-surface mold, and held against the mold by applying a vacuum between the mold surface and the sheet. The vacuum forming process can be used to make most product packaging and speaker casings.
Typically, vacuum formed parts are relatively shallow and require some degree of "draft" or taper to the edges to allow the material to release from the mold after cooling.
Some benefits of vacuum forming parts are an increase in structural strength and enhanced design elements which are not possible using traditional fabrication techniques.
Typically, vacuum formed parts are relatively shallow and require some degree of "draft" or taper to the edges to allow the material to release from the mold after cooling.
Some benefits of vacuum forming parts are an increase in structural strength and enhanced design elements which are not possible using traditional fabrication techniques.
Our Thermoforming Machine

Our forming machine can handle parts that are up to 38" x 38" in size. Preferred forming materials are PETG, Polystyrene, ABS and Acrylic. Choosing the best material for your parts is critical to how well they can be made. We always recommend you speak with one of our Sales Associates while in the design process to best determine materials.
Some typical parts made on vacuum form machines are:
* Packaging Inserts * Industrial Covers * Cases * In Store Displays/Risers
* Dimensional Letters * Robotic Framework * Movie Set Props * Auto Parts
* Electrical Housing Units * Food Molds (Chocolates)
Some typical parts made on vacuum form machines are:
* Packaging Inserts * Industrial Covers * Cases * In Store Displays/Risers
* Dimensional Letters * Robotic Framework * Movie Set Props * Auto Parts
* Electrical Housing Units * Food Molds (Chocolates)
1. A mold is made and prepared.

Molds that are used in a Vacuum Form machine are typically either made from a fibrous wood known as MDO or out of metal (either aluminum or steel). The type of material your mold should be made out of will depend on two factors: the quantity of parts being made, and the required finish a part must have.
Wood Molds are great for small quantity runs of industrial parts because they can be made quickly at a relatively low cost. However, if a part requires a smooth finish wood molds are not always a good idea because they often leave minor impressions of the fibrous grain on the side of the part which comes in contact with the mold.
Metal molds are great for high quantity or high quality pieces because they can be polished smooth and can stand up to long term use without damage or wear. These molds are typically higher cost and require longer lead times.
Wood Molds are great for small quantity runs of industrial parts because they can be made quickly at a relatively low cost. However, if a part requires a smooth finish wood molds are not always a good idea because they often leave minor impressions of the fibrous grain on the side of the part which comes in contact with the mold.
Metal molds are great for high quantity or high quality pieces because they can be polished smooth and can stand up to long term use without damage or wear. These molds are typically higher cost and require longer lead times.
2. Plastic sheet material is heated and pressed against the mold.

A single sheet of plastic is heated to an optimum temperature according to the material type and thickness, and to the complexity of the mold. Our technicians carefully gauge the requirements of each part and lock in precise settings to ensure parts are run in a consistent manner from beginning to end regardless of quantity. These settings are recorded and kept on record so parts can be produced accurately year after year.
3. Vacuum is applied and the plastic is sucked around the mold.

Small holes in the mold cavities help the air vacuum to suck the plastic tightly to the mold. Each mold requires a unique pattern of breather holes to be drilled in it at specific locations to ensure vacuum is applied consistently and strategically. Without these breather holes, technicians would not be able to create precise inner features as shown in the photo to the left.
4. Plastic cools and secondary operations are performed.

The sheet quickly cools and is removed to a neighboring shop location for trimming and other secondary operations such as holes, cutouts and gluing in reinforcing bottoms, caps or other parts. With most parts, the forming process is only step 1 in creating a final part. Final finishing works transforms the formed part blank into a precision part ready for use.
5. The finished product.

This is the finished display product, including pad printing, stickers, labels and other add-ons. This is the type of product our Design Engineers can help you create for your product, production facility or personal use.