Advanced Vacuum Forming Techniques for Complex Shapes

For those who want to mass-produce precise and cost-effective products, it’s hard to beat traditional vacuum-forming techniques. However, traditional methods often fall short when it comes to manufacturing complex pieces with intricate details.

Luckily, vacuum forming has evolved to meet these challenges head-on. Let’s explore how modern vacuuming forming techniques push the boundaries of what’s possible.

What is Traditional Vacuum Forming?

Vacuum forming is the process of heating plastic sheets until they are pliable. Once the plastic is soft, it is formed over a mold. Next, vacuum pressure is applied to ensure the material conforms to the surface of the mold.

While this may sound like a simple process, it requires careful timing, temperature control, and pressure to create a replica of the mold.

While traditional vacuum forming methods are quick and cost-effective, they fall short in replicating complex shapes, namely due to:

• Material thickness: As plastic stretches over deep molds or complex shapes, it naturally thins, often leading to inconsistent thicknesses.
• Detail requirements: Traditional vacuum forming may not capture intricate surface details, particularly those with deep recesses or sharp corners.
• Mold depth: Deep molds may cause the plastic to thin or not fully form.
• Undercuts and reverse angles: To understand undercuts and reverse angles, imagine trying to remove hardened jello from a mold that is wider at the bottom than at the top. Many objects have overhangs that trap the formed plastic part. Unfortunately, traditional vacuum forming methods struggle with these features as the formed plastic must be pulled straight up and off the mold.

Luckily, Painted Rhino offers more advanced vacuum-forming technology, allowing us to:

• Control material thickness
• Capture fine details
• Handle deep molds
• Work with complex shapes
• Ensure quality outcomes

Our Innovative Vacuum Forming Techniques

When projects require undercutting, reverse angles, intricate details, and perfect consistency, we use a combination of techniques that go beyond the traditional.

Multi-Piece Molding

When projects require complex undercutting that would make removing the finished project impossible with traditional methods, we create molds that can be disassembled once the plastic sets. This process ensures precision without compromising strength, thickness, or detail.

Flexible Molds

For pieces that only require moderate undercutting and reverse angles, we may also use a silicone-based mold that can flex around the set plastic during removal. This process allows us to maintain precision without damaging the molded piece during removal.

3D Printing

Traditional vacuum-forming molds are limited in that they take time to produce, often cannot capture intricate details, and are difficult to alter once created. Conversely, 3D-printed molds can be made in a matter of hours or days and are cost-effective to produce. So, on the off chance that you need to produce short runs quickly and cheaply or need to alter the design, we can accommodate you while ensuring you receive high-quality parts that meet your exact specifications.

Combination of Techniques

Every project is unique. And when traditional vacuum forming methods fall short, we get creative, often using a combination of multi-piece molding techniques, flexible molds, and 3D printing to ensure the best outcome. Over the years, we’ve used a combination of methods to create everything from RV products and industrial equipment to medical devices and marine products.

Your Premier Vacuum Forming Production Team

With nearly three decades of experience, we offer the creative solutions you need to bring your vision to life. Whether it’s a custom product or a short run with intricate details, our team is here to assist. Contact us today!