Vacuum Former Training

In the Fablab we have a Formech 508DT Vacuum Former. Below you will find resources to help you with your project. Please don’t use the vacuum former until you have read the material and received an introduction from trained faculty, staff, or TA.

Training Resources

Formech Training Guide

Formech 508DT Training Tutorial

Materials

  • See Materials info from Forming Guide: Materials
  • Standard plastic materials include HIPS, ABS, PETG, Polycarbonate (Lexan).
  • You will make many mistakes trying to figure out the correct settings! Plan on purchasing multiple sheets!
  • Only use the machine for vacuum forming plastic. Approved materials are up to a 1/4” thick Styrene, PETG, and ETFE film.
  • Do not place any materials on top of the machine OR on the EPILOG!
  • Use another table for staging (and please clean up after use).
Sources

Sheet Size

  • The standard sheet size for the vacuum former is 20″ x 18″ (508 x 457 mm). If your material is larger, you will need to cut it down to this size (but not smaller) so that the seal will hold.
  • We have reducing windows which will allow you to utilize smaller sheets of material and minimize wastage.
  • Technical-Newsletter-8-Reducing-windows
  • Reducing Window Sizes: 5″ x 5″ and 11″ x 11″  – Sheets should not be shorter in one dimension than the reducing window.
  • Standard thicknesses are 1 or 1.5mm (1/16″). Thicker materials will require more experimentation and testing.

Molds

  • Molds should be solidly constructed such from wood, clay and plaster (that are sufficiently dried).  Lightweight materials are discouraged since the vacuum pressure may distort the form. If using foam, coat first with plaster of paris or aluminum tape. Make sure all molds are dry before using.
  • Undercuts should generally be avoided.
  • Box molds (with sides perpendicular to the drape table) should be avoided because it will be very difficult to remove the thermoformed plastic from the mold.
  • Be sure that the depth of a hole (female part) in the mold is less than 75% of the width or else there may be material tearing.
  • Webbing may occur with multiple positive (male) molds that are closely spaced.  Spread the molds apart if possible, or consider creating negative (female) molds, which will reduce, if not eliminate, webbing.
  • The vacuum is strong enough to pick up a high level of detail.  If the mold has been milled, you will likely see the tooling in the formed plastic.

Trimming

  • Trimming can be done by hand for single/ small batch methods where the trimmed edge is not critical.
  • Softer less brittle materials can be scored with a sharp blade (roughly half the thickness of the material) and then snapped away from you for a clean break. (Typical materials would be HIPS, ABS, PVC, PP, HDPE & PETG.)
  • Trimming can also be done with a vertical band saw for single / small batches where the trimmed edge is not critical. The band saw can be used for rough cutting or for more accuracy, use a fence or  jig mounted on the table of the band saw. This will leave a slightly jagged edge that may need scraping. Consistency of cut can be an issue.

Formtech Resources

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