Thick sheet vacuum forming is a process used to shape large and thick plastic sheets into specific forms. This method is commonly employed for creating durable, high-strength parts used in various industries, such as automotive, aerospace, and consumer products. Here's an overview of the thick sheet vacuum forming process:
Steps in the Thick Sheet Vacuum Forming Process
1. Material Selection:
- Plastic Sheet: Choose a plastic sheet of appropriate thickness, typically ranging from 1.0 mm (0.4 inches) to 16 mm (0.6 inches). Common materials include ABS,PP,HDPE,HIPS,POLYCARB,PETG,KYDEX,LEXAN
- Heating: in this process, Temperature Detection and Control is very important Real-time temperature monitoring using a mold temperature gun ensures that the mold temperature remains at an ideal level. Adjust the mold temperature according to the characteristics of different materials to achieve the best forming results.Our Vacuum forming master is running this kind of machine from year 1995,he have much rich experience on this,he possess deep knowledge of plastic materials, enabling them to adjust machine parameters according to different requirements, produce various complex vacuum-formed products, and ensure smooth production processes.
2. Forming:
- Mold Preparation: A mold, which can be made of wood, aluminum, or other materials, is prepared and placed in the vacuum forming machine.
- Sheet Placement: The heated plastic sheet is positioned over the mold.
- Vacuum Application: A vacuum is applied, pulling the plastic sheet tightly against the mold. The vacuum removes the air between the mold and the plastic sheet, causing the sheet to conform to the shape of the mold.
3. Cooling:
- The formed plastic sheet is allowed to cool while still in contact with the mold. This ensures the plastic retains the desired shape.
4. Trimming:
- Once cooled, the formed plastic part is removed from the mold. Excess material is trimmed away to achieve the final shape and dimensions. This step may involve CNC machining, laser cutting, or manual trimming.
Key Considerations
- Material Properties: Different plastics have varying forming temperatures and characteristics. Selecting the right material based on the application requirements (e.g., durability, flexibility, UV resistance) is crucial.
- Heating Uniformity: Ensuring the plastic sheet is uniformly heated is critical to avoid defects such as warping or uneven thickness.
CNC cutting
CNC (Computer Numerical Control) cutting is an integral part of vacuum forming manufacturing, which is used to create precise and complex shapes from plastic sheets.After finishing the vacuum forming,then we need cutting the edges and CNC the 3D shapes that we need.
