Thermoforming / Vacuum Forming

Thermoforming Machine

Thermoforming Sample Part

Thermoforming or vacuum forming creates custom parts by heating a plastic sheet; pulling it tightly against a mold corresponding to the desired shape; and allowing the sheet to cool. Thermoforming has these properties:

Possible shapes	3D shapes where the sides are sloped (like a plastic drinking cup) so that the formed part can be removed from the mold.
Example parts	Trays, enclosures, cups, cup lids
Advantages	Low cost for moderate to long runs
Compatible materials	Certain plastics
Compatible machines	Vacuum mold die cut
Alternative machines	None
Tooling	You can choose positive (male) or negative (female) molding. In positive molds the heated material is stretched over the mold and hence the inner side is more accurate. In negative molds the heated material is pressed into the mold and hence the outer side is more accurate.
Precautions	None

When using vacuum forming you design the mold tooling, not the part. For example, to create a part shaped like a drinking cup you would create a mold shaped like a cylinder.

Notes: The thickness of the sheet material will vary at different points of the part due to the stretching that occurs. The part must not be much higher than it is wide.

Thermoforming Applications

Thermoformed plastic is ideal for creating "clamshell" plastic containers for the retail environment, as shown in the sample above right.

As you design a thermoform display package, remember that you can ""sandwich in" a colorful thin cardboard retail display piece which may help sell your product.  It's a good ideas to consult with your retailers about ideal sizes in advance and design your packaging to get you best shelf position.  Small tools and electronic devices are often packaged this way.

Note: This process is planned and currently not supported.