Vacuum forming is a method of thermoforming where high-impact polystyrene plastic is heated and stretched over a mold to conform to the mold’s shape using a vacuum. This technique is popular for creating a variety of products, from signage to vehicle parts and packaging materials.
Unlike pressure forming, vacuum forming is a much simpler process that only uses a single mold. Pressure forming creates products by pressing two molds together to shape the thermoplastic.
Vacuum Forming Process
The first step in the vacuum forming process is the vacuum forming mold is placed into its machine and heated. Then, the plastic is loaded onto its carrier and also heated. Once the material is ready, the mold is raised into the sheet and a vacuum force draws the plastic tightly over it. The plastic is then cooled, where it solidifies and hardens. Finally, the mold is then removed, creating the finished product.
Popular Applications for Vacuum Forming
Auto Parts
Many of a car’s solid features are created using vacuum molds. For instance, decorative interior paneling, car bumpers, and cup holders can be made with thermoformed plastic using vacuum pressure. Vacuum forming is an efficient and low-cost option, especially for creating parts with unique shapes, dimensions, or cutaways.
Packaging
Vacuum forming is cost-efficient for standard and nonstandard plastic containers such as to-go containers, protective inserts for boxes, unique plastic store displays and toothbrush handles. When specific brand guidelines must be followed, a vacuum mold can be designed to match these specifications, including coloring abilities.
Children’s Toys
Children’s toys can be easily made using a vacuum forming solution. Vacuum molds can be created with small, intricate crevices for highly detailed and small designs for dolls, action figures, toy vehicles, and more.
Medical Products
Vacuum forming can create a viable packaging solution for sterile environments where product integrity is an absolute must. It can also be used to create hardware like medical beds and machinery parts used in treating patients each day.
Luggage and Storage
Affordable, durable and lightweight luggage can be made at scale in a variety of shapes, colors, and textures using vacuum forming. It can also be used to create parts with holes in specific locations for attaching fasteners. In addition, vacuum forming is a great solution for creating plastic storage containers that are popular for moving and storage.
Electronics
Custom parts for a variety of electronics can be made from vacuum forming. This is a great way to create unique parts like video game controllers, ergonomic keyboards, housing for screens, remote controls, and laptop casings.
When is Vacuum Forming Not Suitable?
Vacuum forming is not suitable for products containing highly complex or asymmetrical geometries. Instead, it is best suited for products that are relatively uniform in their dimensions.
Benefits of Vacuum Forming
One of the most widely appreciated benefits of vacuum molds is that they can be reused consistently to create products at high speeds. This results in less time waiting for materials to arrive at your facility and also allows you to prep your products to go to market efficiently.
Additionally, vacuum molds can save money on overhead costs for manufacturing product parts. Their reusability creates a one-time expense for product design and in most cases, larger orders can also bring down the cost per unit.
When sourcing raw materials, the ones used in vacuum forming are usually easily obtained and inexpensive. If changes to the mold need to be done, it will not cost much money because of how quickly they can be created. Finally, vacuum molds are durable and anti-corrosive, meaning that any product loss will be minimal.
With vacuum molds, you can create multiple sizes of the same product mold while maintaining accuracy, allowing you to scale your operations to offer the same product in multiple sizes. This is great for product lines like luggage where replicating the same design is integral to brand strategy.
Lastly, vacuum-molded products are lighter than materials like metals, wood, and other plastics and can transport more units of product affordably.
A Better Consumer Experience
Vacuum molds are typically more visually appealing than other packaging. They can be made in nearly any color, size, shape or texture. Vacuum molds allow manufacturers to create a wide range of products with high attention to detail. The lightweight packaging also makes them easy to transport.
Get Vacuum Forming Solutions for Your Business Today
Foam Molders & Specialties offers completely U.S.-based vacuum forming solutions that are customized for your business. To learn more, contact us at any time.
