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Vacuum Forming Services Near Me: How RapidMade Can Help Maximize Efficiency and Quality

If you’re in need of vacuum forming services, you’re probably wondering, “Are there any plastic shops near me that can help?” The good news is that your search ends here! Whether you’re looking to prototype a new product or mass produce a specific part, RapidMade is your go-to resource for maximizing efficiency and quality in vacuum forming.

Vacuum forming is a highly versatile and cost-effective process for creating plastic parts and packaging. By heating a plastic sheet and vacuuming it over a mold, intricate shapes can be achieved with ease. But what makes our shop so special?

Firstly, our proximity in the Pacific Northwest, specifically the provincial state of Oregon, ensures quick turnaround times, reducing your production timeline. You won’t have to wait for parts to be shipped from distant suppliers or pay exorbitant freight costs. And you don’t pay the sky high rent and taxes typical in California. Secondly, our expertise and experience guarantee superior results. With knowledge of various materials and techniques, we can provide valuable advice and tailor their services to meet your specific needs.

So, when it comes to vacuum forming services, why settle for anything less than the best? Choose RapidMade and experience the efficiency and quality that will take your project to new heights.

The Thermoforming Process

Fundamentally, thermoforming works by drawing a hot sheet of thermoplastic down onto a mold. Each draw uses a single sheet. These sheets can be formed into one or multiple parts depending upon the size of the part. Increasing the number of parts created per draw is one of the best ways to decrease the cost per part of thermoformed products.

After the hot thermoplastic has been drawn down over the mold, a vacuum may be used to suck out any air and accurately reproduce the details of the mold. This process is referred to as vacuum forming. Once the part has cooled, any excess plastic from the sheet is trimmed away leaving a finished part. These cuts can occur at the base of the part, along the wall or in any number of custom variations to create features like holes and slots.

Before thermoforming can begin, tooling needs to be made. These molds and trim jigs can be 3D printed, cast, or machined. If the final product is going to be translucent or transparent, the mold may need custom finishing like sanding or polishing in order to achieve optimal surface finish as the finish will pick up on the tool side of theparts. Depending upon the technology and material used, the lifetimes of these molds can range from hundreds of forms to permanent tooling for unlimited forms.

Thermoforming Materials

Thermoforming materials like HIPS, PETG and ABS offer a range of mechanical, chemical and aesthetic properties. Thermoformed parts can rigid or flexible; transparent or opaque; and food-safe, heat-resistant, chemical-resistant, or UV-resistant. Below are our most commonly used materials for thermoforming. To get more information about any material, check out the included data sheet for all the specifications.

HIPS (Polystyrene)

Our most commonly-used material. Inexpensive, functional material that can be brittle at low temperatures and can off-gas at higher temperatures. Used for packaging trays, covers and light-duty structural pieces. Food-safe versions available.

HIPS Data Sheet

PETG (Polyethylene Terephthalate) (Polyester)

Moderately inexpensive material with good water and oxygen barriers. Able to stand up to substantially lower temperatures than HIPS. Often used for food-safe applications, freezer packaging and water bottles.

PETG Data Sheet

ABS (Acrylonitrile Butadiene Styrene)

Medium-cost impact-resistant engineering plastic which can be flame retardant or UV resistant when blended with other materials. Used for high-end packaging and moderate-load structural components.

ABS Data Sheet

Kydex T (ABS/PVC) or Kydex 100 (Acrylic/PVC)

Expensive flame-retardant engineering plastic with high impact resistance. Used for moderate-load structures, covers and enclosures that require fire resistance. Kydex 100 is our go-to material for radomes.

Kydex Data Sheets

PC (Polycarbonate)

Medium- to high-cost engineering plastic with high stiffness, impact strength and temperature resistance, plus options for UV and scratch resistance. Often used for glass replacements on phones, TVs, lights or glasses, as well as high-temp applications. Harder to form than most thermoplastics, especially for fine details.

PC Data Sheet

PE, HDPE or LDPE (Polyethylene)

Moderately hard, inexpensive plastic with high chemical resistance. Does not off-gas at high temperatures. Chemical and thermal durability makes it well-suited for chemical-resistant containers. Higher shrink rate than other materials, which lowers tool life and increases variability between parts.

PE Data Sheet

PP (Polypropylene)

Moderately-priced alternative to PE which improves thermal and mechanical properties. Higher level of chemical resistance than most plastics. Can be used as an engineering plastic. Used for chemical-resistant applications, including food contact.

PP Data Sheet

PVC (Polyvinyl Chloride)

Hard engineering plastic with strong mechanical properties as well as high chemical and electrical resistance. Can be made rigid or flexible. Used for certain chemical-resistant containers.

PVC Data Sheet

Acrylic

An inexpensive, rigid and brittle plastic with relatively high UV resistance. More difficult to form than other plastics. Not intended for tight bends or details. UV resistance makes it well-suited to outdoor applications.

Acrylic Data Sheet

Molds for Thermoforming

Traditionally, molds for thermoforming have been machined from urethane or aluminum. Now, 3D printing has become an excellent choice to produce tooling for parts smaller than 11” x 15”. 3D printed molds, especially those produced with Multi Jet Fusion printing, significantly lower the cost per part and speed up production time when compared to machined molds. Moreover, they can easily achieve complex shapes like undercuts that would be expensive or impossible to machine.

Ultimately, each technology offers different strengths for the tooling process. Molded tooling, for example, is good for creating multiple long-lasting molds. Machined tooling is a better option for making large molds, and, depending on the material used, can be permanent or semi-permanent. Even among 3D printed molds, there are different ideal applications for each type of 3D printer.

Thermoforming Design

Types of Molds

Multi Jet Fusion (MJF)

  • The overall best tooling option for parts smaller than 15”x11”
  • The cheapest print option
  • High accuracy
  • Permeant tooling
  • Generally does not require additional finishing for opaque plastics

Aluminum-Filled Urethane

  • Create long-lasting tooling or multiples of a tool at a lower price than printing
  • Requires a 3D printed or machined master mold
  • Permanent tooling
  • Cheaper to reproduce in multiples than 3D printing, easily get high level of finish for polished parts

Machined Wood/MDF

  • Absolute cheapest option for medium to large tools for prototyping
  • Life is less than 50 forms
  • Poor to average accuracy

Machined Urethane Foam

  • The best option for larger, permanent tools where matte surface finish on tool face is acceptable
  • Average to good accuracy

Machined Aluminum

  • Permeant tooling
  • Used for automated, high-volume production with fast heating and cooling cycles
  • Good to excellent accuracy
  • Best surface finish of any mold, needed for high polish on mold side or clear parts

Applications of vacuum forming in different industries

Vacuum forming has a wide range of applications in various industries. Its versatility makes it suitable for a multitude of products and parts. In the automotive industry, vacuum forming is commonly used for interior trim components, such as dashboards and door panels. The process allows for the creation of complex shapes and textures, providing a high-quality finish.

In the packaging industry, vacuum forming is widely used for creating trays, clamshell packaging, and blister packs. The ability to customize the shape and size of the packaging ensures that products are securely held and protected during transportation. Vacuum formed packaging also provides an excellent display for retail products, enhancing their visual appeal.

The medical industry also benefits from vacuum forming services. It is used for creating medical device enclosures, instrument trays, and custom packaging for pharmaceutical products. Vacuum formed parts can be easily sterilized and are resistant to chemicals, making them ideal for medical applications.

Common challenges in vacuum forming

While vacuum forming offers numerous benefits, it also comes with its own set of challenges. One common challenge is achieving consistent wall thickness throughout the formed part. Variations in material distribution can lead to weak spots or structural issues. To overcome this, RapidMade employs various techniques such as adjusting heating temperatures, optimizing vacuum pressure, pre-stretching material and using mold designs that promote even material flow.

Another challenge is the formation of surface defects, such as air bubbles, webbing or wrinkles. These defects can affect the aesthetic appeal and functionality of the final product. RapidMAde uses different methods to minimize or eliminate these defects, including using textured molds, adjusting heating and cooling cycles, and employing proper sheet handling techniques. Many of these defects are a result of poor part or mold design and require an experienced engineer to catch these potential issues up front in order to avoid costly tooling rework.

Factors to consider when choosing a plastic shop for vacuum forming services

When selecting a local plastic shop for vacuum forming services, there are several factors to consider. Firstly, look for a shop with a solid reputation and a track record of delivering high-quality results. Check their portfolio and client testimonials to gauge their expertise and experience in vacuum forming.

Secondly, consider the shop’s capabilities and equipment. Ensure that they have the necessary tools and machinery to handle your specific project requirements. Ask about the range of materials they work with and their ability to customize colors and textures.

Another crucial factor is the shop’s customer service and communication. A good local plastic shop will be responsive to your inquiries, provide regular project updates, and be open to discussing any concerns or modifications. Effective communication is essential in ensuring that your project is executed according to your expectations.

RapidMade has a team with decades of experience, a robust engineering team and a sales team that is available around the clock, millions of dollars invested in equipment including formers and cutters 10 feet long, and a 25,000 square foot facility. In short we are your one stop shop for parts large and small.

We encourage you to fill out the lead form at the top of the page to get a quote for your project. We know you won’t be disappointed with the end product or the process it takes to get there.