Vacuum forming, or 'Thermo' technology, is one of the most common and oldest techniques used to process various materials and products.

The process involves a plastic sheet that is heated to a specific temperature until it is soft and malleable to be draped over a mould that it can fit into. A high-quality vacuum is then applied, and it carefully sucks the sheet into the mould and ejects it when completed. Such a method uses advanced heat, pneumatic, and hydraulic controls to achieve more detailed, faster applications.

Agricultural components

It is often utilised throughout the agricultural industry to create a vast range of plastic components to help enhance processes, such as heavy-duty machinery and transportation vehicles.

Automotive parts

Vacuum-formed plastics are a restorative material employed for use in the automotive industry, helping in functional and aesthetic areas. Everything inside a car, including the door panels, dashboard and various other controls, are often designed and curated with thermoforming.

Packaging

Plastics utilised during the process are ideal for the purposes of packaging. Vacuum forming is a cost-effective method perfect for large production lines. They are essential for packaging as they are hygienic, durable and provide a broad range of size and shape options.

Place the mould into the vacuum former

Once the mould has been made, it is sufficiently placed into the machine's vacuum former. Above the mould, a plastic sheet is clamped above. 

Position the heater above the plastic

The heater inside the machine's former is placed above the plastic, where the sheets are heated to warm up the plastic and make it more flexible and susceptible to being moulded. 

Move the shelf towards the plastic

The plastic must then be set at the proper temperature for successful moulding. Professionals can then use a handle to move the shelf of the positioned mould upwards so that it sits perfectly on top of the plastic. 

Switch the vacuum former on

Finally, the vacuum former removes all the air from its machine once switched on, which enables the plastic to curate the right shape.

MDF is one of the best-used materials for creating moulds at a fast speed, which is ideal for smaller production runs. Unlike cast ones, such moulds can wear out, and the joint marks made in plastic material or sheets can be more visible. 

A vast number of companies worldwide use techniques and methods like vacuum forming to curate and manufacture various acrylic or plastic-based products. Many use vacuum forming as a way to make automotive and industrial components, trays, enclosures, film and stage props, POS retail displays, signage, rapid prototyping and product development.

One of the best and most commonly utilised plastic materials for vacuum forming is HIPS (High Impact Polystrene Sheeting), and this is due to how flexible it is; it can be successfully moulded into any shape at all. Another plastic that is also of similar status in the industry and used for vacuum forming is PC (Polycarbonate).