Finding a manufacturer for a part with non-standard dimensions or specific material needs often involves a lengthy vetting process. This search becomes more difficult when a design’s complexity tests the limits of the vacuum forming process.
Formed By Makers provides custom vacuum thermoforming for various part requirements. We manufacture parts that have complex geometries and demanding material specifications.
Read on to learn more about the quality and value our vacuum thermoforming process delivers.
What is Vacuum Thermoforming and How Does it Work?
Vacuum thermoforming is a manufacturing process that shapes plastic sheets into three-dimensional parts. It begins by heating a thermoplastic sheet until it becomes pliable, and a vacuum then draws the softened material tightly over or into a mold to form the final part.
Workers start by clamping a plastic sheet into a frame and moving it to a heating station. Once the material reaches its forming temperature, we position it over the mold and apply the vacuum. Atmospheric pressure forces the plastic against the mold's surface, where it cools and solidifies into its new shape before being removed for trimming.
Benefits of custom vacuum thermoforming include:
- Lower Tooling Costs: This manufacturing method is economical for low to medium production volumes due to less expensive tooling.
- Faster Production Speed: Shorter lead times for tooling and part production allow for quicker project completion.
- Large Part Capability: The method is well-suited for manufacturing large parts that are costly to produce with other techniques.
- Material Flexibility: A wide range of thermoplastic materials, colors, and thicknesses can be used to meet part requirements.
- Efficient Prototyping: The low cost of tooling makes this technique practical for creating prototypes and iterating on designs.
Custom Vacuum Thermoforming from Formed By Makers
At Formed By Makers, we manufacture custom plastic components for industrial and consumer applications. We take a project from the initial design concept through the final production run to create parts that meet precise specifications.
Quality control is a component of each stage, starting with material selection and finishing with a final inspection. Documentation of every batch maintains consistency across an entire order and for any subsequent manufacturing. We adjust our equipment for the specific material and shape of each part to produce uniform results.
We offer the following value-added services to complement our custom thermoforming services:
CNC Routing
We use 3-axis CNC routing to trim thermoformed components and machine flat sheet materials. Our equipment is set up to handle plastics, wood, tooling board, and aluminum for both single prototypes and production runs. This method produces finished parts with sharp edges and precise dimensional accuracy.
Forming Molds
We manufacture vacuum forming molds in-house using wood, urethane, and aluminum. The choice of material is determined by the project's production volume, budget, and durability requirements. This allows us to create accurate tooling that is optimized for the specific application before manufacturing begins.
Trim Fixtures
We create custom trim fixtures to hold vacuum-formed parts in place for precise cutting. These fixtures are CNC-machined from materials like wood or urethane to match the exact contours of a component. Using a fixture ensures that every part is trimmed to the same specifications for a consistent final product.
Design and Prototyping for Automotive and Consumer Products
We create automotive and consumer prototypes by turning an initial concept into a manufacturable design. Physical prototypes are created to test and validate the part's form and function before any production tooling is made. The project concludes with the delivery of a complete package of CAD files and drawings ready for manufacturing.
Vacuum Thermoforming Applications and Industries
The adaptability of vacuum thermoforming makes it a valuable manufacturing method for many industries and products. It is frequently used to produce large, durable, and lightweight parts for a wide range of commercial and industrial applications.
- Automotive: Automakers rely on this technique for interior and exterior trim panels, protective covers, and custom housings.
- Medical: Equipment enclosures and protective components for various devices are common applications.
- Industrial: For industrial settings, we create machine guards, equipment covers, and other custom protective components.
- Packaging: Creating display cases, protective packaging, and product presentation solutions is another frequent use.
- Agriculture: Durable panels, fenders, and interior components for tractors are produced for the agricultural industry.
- Electronics: We also manufacture custom cases and protective covers designed to house sensitive electronic equipment.
Custom Thermoforming vs. Other Manufacturing Processes
View the table below to see how the most common manufacturing alternatives compare based on factors like tooling cost, production volume, and design complexity.
| Vacuum Thermoforming | Injection Molding | Pressure Forming | |
| Tooling Cost | Low | Very High | Medium |
| Best Production Volume | Low to Medium | High to Very High | Medium |
| Part Complexity | Low (simple shapes, rounded corners) | Very High (intricate details, sharp corners) | High (sharp details, textures) |
| Lead Time | Short | Long | Short to Medium |
| Ideal Use Case | Large parts with simple geometry (trays, covers, liners) | Small, complex parts in massive quantities | Cosmetic housings, parts needing sharp detail |
| Part Size Capability | Excellent for large parts | Best for small to medium parts; large parts are very expensive | Good for medium to large parts |
Common Materials in Vacuum Thermoforming
We select a thermoplastic based on the part's final application. This choice depends on the required durability, environmental exposure, and the overall project budget. Each material offers a distinct balance of these attributes.
Acrylonitrile Butadiene Styrene (ABS) is valued for its toughness and rigidity, while ASA/ABS co-extruded sheets combine the structural strength of ABS with the superior UV resistance and weatherability of Acrylonitrile Styrene Acrylate (ASA), making them ideal for outdoor applications.
High Impact Polystyrene (HIPS) serves as a cost-effective option for many applications. Materials such as PETG offer excellent clarity for transparent parts, while Polycarbonate provides superior impact strength for more demanding environments.
Partner With Formed By Makers for Custom Vacuum Thermoforming Services
Custom vacuum thermoforming is an effective method for producing durable plastic components for a range of industries. The technique balances tooling costs, production speed, and material options to meet specific project needs.
At Formed By Makers, our capabilities are structured to handle projects with demanding technical requirements. In-house tooling and CNC trimming allow us to maintain quality from the initial design through the final part.
Click below for a quote and to learn more about how we can assist with your next project.
