Here at Stephens Plastic Mouldings, we are proud to offer a wide range of plastic manufacturing services. Therefore, we can accommodate many different requirements, applications, and sectors. One of the services we offer is vacuum forming – a process you may have heard of, but might not be sure what it entails.
However, if you look around you right now, it is likely that you will be able to see vacuum formed products everywhere. Some of the common products include:
- Traffic light housing
- Plastic bottles
- Bathtubs
- Kitchen utensils
It is one of the most diverse plastic fabrication processes on the market. It can transform one sheet of plastic into almost anything you need. So, we now know what vacuum forming is: a type of plastic fabrication technique. So how does it work?
Related: What Is Vacuum Casting & Why Is It Used?
How Does Vacuum Forming Work?
Although the process can sound a bit complicated, in fact the stages of vacuum forming are relatively simple. This is providing the vacuum forming company has all of the necessary tools and equipment.
1. Firstly, a plastic sheet is heated across its entire surface area. This is throughout its thickness until it reaches its forming temperature.
Different plastics will have different forming temperatures so the target temperature will vary from plastic to plastic. The forming temperature is when the sheet becomes soft and pliable – and therefore can be fabricated into different shapes.
2. Once the sheet is at its forming temperature, it is then draped over a surface or a mould of the desired product shape.
3. Then a low-pressure vacuum is applied to it. This vacuum essentially sucks in the sheet plastic and forces it against the mould. As a result of this, it produces the shape of the product you require.
4. Next, once the plastic has set into the mould shape, it’s taken out of the machine and any excess material is trimmed.
We use various trimming methods and tools. During this stage, we create necessary holes, slots, or cut-outs in the component, as well as perform any decoration or assembly.
Vacuum Forming Plastics
Put simply, vacuum forming transforms sheet plastic into an item of choice. When it comes to choosing the materials, most thermoplastics will be suitable for the process. Each thermoplastic comes with its own set of properties which will help you determine whether it is right for the product you have in mind. Some of the most common vacuum forming thermoplastics are:
- Acrylic
- Polyethylene
- Polycarbonate
- Polystyrene
Advantages Of Vacuum Forming
After you have discovered what it is, it is likely that you want to know advantages of vacuum forming. There is a lot that comes with this type of plastic fabrication. It offers endless possibilities of products in many different shapes and sizes. Due to the nature of the process, as long as you can produce a mould for it, you can use it to make almost any shape.
Whether you are looking for a regular production line or you are looking for a one-off product, vacuum forming could be the best solution for you. The process is fast and requires little labour. This means that it is incredibly cost-effective in comparison to other plastic manufacturing processes. Additionally, because of the low-pressure vacuum process, the mould doesn’t need to be made from a particularly high-quality material, which can also save you money. Mould fabrication time is also reasonably fast, making vacuum forming a much more economical and faster option than other plastic fabrication methods.
FAQs
What are the cost benefits of using plastic injection moulding for my business? Plastic injection moulding offers significant cost benefits, particularly for high-volume production. The process minimizes material waste, reduces labor costs, and allows for the integration of multiple features into a single component, eliminating the need for assembly. These factors contribute to a lower overall production cost.
How does plastic injection moulding compare to vacuum forming in terms of production speed and efficiency? Plastic injection moulding is generally faster and more efficient for high-volume production compared to vacuum forming. Injection moulding produces complex parts with excellent repeatability at high speed, while vacuum forming suits simpler shapes and lower-volume production better.
How can I determine if plastic injection moulding or vacuum forming is right for my project? The choice between plastic injection moulding and vacuum forming depends on several factors, including the complexity of the part, production volume, material requirements, and budget. Injection moulding is ideal for high-volume, complex parts, while vacuum forming is better suited for larger, simpler parts and lower production volumes.
Stephens Plastics Services
Stephens Plastics have years of experience in all forms of plastic fabrication. Are looking for more information on what vacuum forming is? Or, would like to find out more about our vacuum forming services? Then please get in touch with us today.
Found this blog post helpful? Check out our other blog posts on What Makes Plastic Injection Moulding So Popular? or A Quick Guide To The Metal Casting Process.