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About Vacuum Forming
Vacuum forming is a plastic thermoforming process that
involves forming thermoplastic sheets into three-dimensional shapes through
the application of heat and pressure. In general terms, vacuum forming
services are all sheet forming methods, including drape forming, which
is one of the most popular services. Basically during the vacuum forming
process, plastic material is heated until it becomes pliable, and then
it is placed over a mold and drawn in by a vacuum until it takes on the
desired shape. Vacuum thermoforming is a great method for producing plastic
parts that have sharp details and fit nicely to specific products.
During the vacuum forming process, a sheet of heated plastic material
is placed over a male or female mold. The mold then moves towards the
sheet and presses against it to create a seal. Next, the application
of a vacuum draws out the air between the mold and the sheet so that
the plastic conforms to the mold exactly. This is accomplished through
venting holes in the mold that are joined to vacuum lines. The mold also
has a water cooling system integrated into it that brings the temperature
of the plastic to the set temperature needed. When the curing temperature
is reached and the piece is formed, air blows back into the mold and
separates the new part from the mold.
Vacuum forming services produce plastic parts for various industries,
such as the food, cosmetic, medical, electronics, entertainment, household
products, toys, athletic equipment, appliance, automotive, office supplies
and clothing industries. One of the most important industries that thermoforming
serves, however, is packaging. Products like blister packs, inserts,
trays and clamshells are used to house other products and are important
for both preservation of the items they hold and the aesthetic designs
they can provide. Consumer product manufacturers often use vacuum forming
to produce plastic trays and glasses. Another interesting use for vacuum
formed plastic is the creation of signs for gas stations and convenience
stores.
The greatest advantage to vacuum forming services is that it involves
less parts and tooling than injection molding, and therefore is more
cost-effective. It is an economical choice that can be used for small
and medium production runs, with low cost tool modifications. There is
great design flexibility available, from a variety of prototypes to custom
made designs that can be used to cover almost any product. Most manufacturers
also offer a wide variety of trim and other decoration options that can
prove quite a visual advantage. Time of production is generally short,
which frees up time to do more detail-oriented aspects of production.
Sharp, precise detail is available for many products, which makes vacuum
formed plastics an attractive alternative to other molding processes.
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Types of Vacuum Forming
- are clear plastic, nonresealable packaging used for products that could be tampered with.
- are plastic packages that have hinges to open and close like a clam’s shell.
- is like snapback forming except
that the thermoplastic sheet is stretched to the base of the mold.
In both cases, the use of air to stretch the material prior to vacuum
sealing and application to the mold permits the material to thin uniformly.
- is a thermoforming procedure that uses a plug or male
mold to press the heated thermoplastic material into the female mold
prior to the application of a vacuum. This method helps uniformly
distribute the sheet.
-
is a thermoforming procedure that involves applying pressure to the
top of the plastic sheeting while the vacuum force pulls downward. Pressure
forming is done through air pressure or mechanical means, and provides
greater precision because the plastic is able to attain a greater definition
of shape in the mold.
- is the process of pre-stretching the sheet
material with a vacuum box. A partial vacuum is then applied
to the box, just enough for the necessary stretching, and the mold
is
pushed
into the material where the box is vented to atmospheric pressure
that draws on a vacuum.
- is vacuum thermoforming using only female
molds that produce a material distribution that is the opposite
of the results
obtained from male molds.
- involves heating and stretching plastics.
- are created by a thermoforming process that uses a vacuum to suck the plastic sheet into a mold.
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