Vacuum Forming

TEAM Lab Hardware

Formech 450 DT

 

Forming Area: 17 x 11inches (430 x 280mm)

Sheet Size (absent reducing frames): 18 x 12 in (450 x 300mm)

Maximum Material Thickness: 0.25in (6mm)

Heating Zones: 4

Key Features

• Reducing windows (for working with smaller stock)
• Vacuum release
• Digital controls and profile memory

Link to manufacturer's website

Materials

All materials compatible with this process are thermoplastics. Common materials are listed below

Examples

• The following series of images depict the process (captured from video on Formech Website)

Vacuum Forming Gallery

Click here to view more example vacuum formed parts

Rates

• Note: We strongly recommend submitting a service request to obtain an accurate project cost estimate. Self-quoting can often lead to miscalculations

We bill for time and materials while using this service. For time, we assess an hourly rate for Staff time (Profesional, or Student staff where possible).  For sufficiently large projects, we can also train an operator for use of our machine and assess a lower "unassisted" rate thereafter.  For materials (sheet-stock) we seek at-cost reimbursement for internal clients, and at-cost+NUD for external.  Note that most projects will require development services (and associated fees) to design the required mold body.

*NUD = university required "Non-University Differential"

Technical Details

Our Formech 450DT thermoforming machine can produce high quality molds in minutes. These custom molds can be configured to various materials, patterns, and forms.

Vacuum forming is a process whereby sheets of thermoplastic are heated to their softening point (forming temperature), stretched over a single-surface mold, and held in place to cool via vacuum pressure. The resultant part conforms to the surface of the mold, but is generally uniformly thick. Parts generally need to be cut/trimmed from the bulk plastic thereafter.

Applications for this process consist of any design involving a complex shape of uniform thickness (polymer materials only). Specific examples include casting chambers, and orthotics, enclosures, dental components, and packaging.

Mold Design and Manufacturing:

Molds for vacuum forming can be fabricated from a wide array of materials, including wood, machined or hand-formed thermoplastics (assuming sufficient thermal stability during processing), 3D printed polymers, and various metals. To ensure successful vacuum-formed part production, molds should be designed without overhangs and ideally incorporate draft angles to minimize the potential for adhesion between the part and the mold. The mold material must possess the capability to withstand elevated temperatures for a duration of approximately one minute and resist deformation under the mechanical forces generated by the vacuum during the forming process.

Trimming:

A precise approach for trimming vacuum-formed parts may necessitate use of laser cutting along the perimeter of the formed sheet, contingent upon compliance with safety protocols and compatibility with the laser cutter's working envelope. Alternatively, manual trimming methods, such as the use of shears or rotary cutting tools, may be implemented based on the specific requirements of the component.

Edge Finishing:

To achieve a more refined edge finish, rough-cut edges of vacuum-formed parts can be smoothed using localized heat, typically applied via a reflow soldering station, resulting in a more polished and aesthetically pleasing appearance.

Embedded Metals and Other Materials:

To augment the mechanical strength of vacuum-formed components, TEAM has utilized an advanced technique of incorporating metal inserts (typically laser cut) between multiple layers of vacuum-formed polymer, effectively encapsulating these elements during the thermoforming process.

Safety:

Utilize only polymers that are verified as safe for vacuum forming applications. Researchers intending to experiment with novel materials or methodologies must consult with the TEAM lab manager prior to procurement to ascertain both safety and material compatibility.