Thermoforming

Owned by Jasmine Thind
Last updated: Oct 26, 2022
2 min read

Thermoforming will be used for our headlight, tailgates, and windshield design. Trials will be done to better understand the parameters of thermoforming and prepare for when it comes to final design.

All information and results from trials will be noted in the subpages.

Our Machine:

The machine we have in the bay is the Centroform EZFORM LV 1827 110V Tabletop Vacuum Forming Machine.

Features/Tips:

  • Uses a 110 -120 volt 1500 Watts (approximately 12.5 amps) heating element

  • A vacuum source is required - household vacuum/shop vac or a vacuum pump could work

  • The small brass outlet can be used for an electric pump to be for added suction

    • Both the suction sources can be used at the same time and the transition from one vacuum to the other will be automatic

      • If the brass outlet is not used be sure to cap it

  • The two handles on the sounds should be turned anti-clockwise to release and opposite to tighten

  • The mold should always be smaller then the platen by at least ½ to 2 inches from each side

  • The oven takes about 2-3 minutes to warm up

  • The plastic sheet should be placed into the frame

  • 2-3 inches of sagging of the sheet is a good estimate of when it is ready

  • The plastic must be heated evenly, including all 4 corners, use a rounded stick or pencil on the corners to test

  • The mold should be either warm or at room temperature, keep it on the platen as the plastic heats for warmth

  • Turn on the suction sources and bring the frame down, the vacuum will force the plastic to be sucked over the mold

  • Wait for the plastic to be completely cold before pulling it off

  • If the mold and plastic are stuck together, compressed air can help (blow in between)

  • Beware that different plastics may heat differently, if a plastic starts to develop air bubbles, it has absorbed moisture and may need pre-drying before hand

Troubleshooting:

There a common problems that can happen:

Webbing ( plastic folds on itself):

  • Plastic might be too thin

  • Mold might be too detailed/awkward

  • Plastic might have stretched too much

  • Raise the mold by placing a wood cut out on the bottom

  • Too much vacuum could have been applied too fast - try to regulate the vacuum air or use only electric pump

  • Too many sharp corners/ shapes

Plastic not sucked over the mold:

  • Mold is too large or tall

  • Heat the plastic for longer or use a thicker plastic

  • Ensure adequate suction and no leaks

Not enough detail on the formed parts:

  • Drilling tiny (1/16 inch) holes in the mold in parts where the vacuum will have a hard time pulling can help

  • Make sure vacuum has no leak, check filter

  • Use thinner plastic or heat it longer