College of New Caledonia/Design and Fab Lab
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Vacuum Forming

Thermoforming plastic sheets over 3D molds

Overview

Vacuum forming heats plastic sheets until pliable, then uses vacuum pressure to form them over a mold. This process is excellent for creating packaging prototypes, product casings, display pieces, and custom enclosures. Quick turnaround for multiple copies from a single mold.

Available Equipment

  • Formech 508FS - 20x20 inch forming area, up to 6mm sheet thickness
  • Mayku FormBox - Desktop unit, 7.9x5.7 inch area, quick prototyping

Form Time

2-5 minutes per piece

Materials

PETG, ABS, HIPS, Styrene

Training Required

Orientation required

Guidelines

  • 1. Molds must have draft angles (5-7 degrees) for release
  • 2. Avoid undercuts in mold design
  • 3. Use heat-resistant materials for molds (MDF, 3D printed with high-temp filament)
  • 4. Allow adequate cooling time before removing formed plastic
  • 5. Trim formed pieces carefully using band saw or rotary tool