While we may not realise it, vacuum forming is responsible for an enormous amount of the products we interact with on a daily basis. From your car’s dashboard to your bathtub, vacuum formed products are an essential part of our lives. So, in this article, we’re going to shine a light on this underappreciated manufacturing method and walk you through 16 products that are vacuum formed.
Everyday Products That Are Vacuum Formed
A vacuum forming machine, like the Thermoformer SC 240, can produce plastic-based products at an immense scale and a relatively low cost. This convenience and affordability make vaccum formed products an extremely popular choice in a wide range of industries, from the automotive sector to healthcare. Keep reading to discover which products you encounter daily have been produced through vacuum forming.
Vacuum forming was invented by Alexander Parkes in 1855 after he noticed thin sheets of plastic would bend when heated by steam and maintain their shape once cooled. However, it wasn’t until the mid-20th that the first vacuum forming machine was patented, and vacuum formed products began to hit the mainstream market. In these early stages, vacuum forming was mainly used to produce household products and toys. However, as technology developed, vacuum forming machines could create intricate designs used in a wide range of products.
Put simply, vacuum forming is the process of using heat to manipulate the shape of plastic sheets. It’s one of the most popular methods for making lightweight, customised components like packaging, protective covers, and liquid containers. It is called ‘vacuum forming’ as it involves using a vacuum to remove the air between the heated plastic and a template. This vacuum causes the plastic to fully conform with the template, capturing precise details. This is what differentiates the process from thermoforming.
Vacuum forming has quickly become one of the most popular manufacturing methods in the world for several reasons:
- Cost-effective: Generally, vacuum forming is more affordable than other moulding techniques like injection moulding or blow moulding.
- Versatile: A wide range of thermoplastic materials can be vacuum formed, allowing for plenty of variation in thickness, colour, and surface finish.
- Quick: The vacuum forming process is very quick, allowing for production at an immense scale.
- Prototyping: Low production cost and extensive design flexibility mean vacuum forming is well suited for prototyping and low-volume production runs.
Before we take a look at some of the most common products that are vacuum formed, it’s important to understand the vacuum forming process. In most cases, there are five stages to vacuum forming:
- Make The Mould: A mould is constructed in the shape the plastic will form around. The mould should have tapered sides so the plastic can easily be released from the mould.
- Setting Up The Machine: Once the mould has been created, it needs to be placed in the vacuum forming machine. The plastic sheet will be placed above the mould, and the heater will be above the plastic sheet.
- Heat The Plastic: The plastic should be heated enough to ensure it is fully flexible but not so much that it damages the sheet. The machines we stock at O’Leary Engineering are designed to maintain the correct temperature at all times.
- Apply The Vacuum: The plastic is pulled onto the face of the mould. The vacuum pump is activated, and the plastic takes on the shape of the mould. This must be done quickly so the plastic remains warm and malleable.
- Cooling And Trimming: Before it can be released, the plastic needs to cool and harden. Fans can be used to reduce the time it takes. Once cooled and separated, the plastic sheet will be trimmed so it is ready for use.
You may not realise it, but vacuum formed products are all around us. They’re an integral part of some of the world’s most important industries, making day-to-day life easier for so many people. Let’s look at some of the most important vacuum formed products below:
Automotive Products
The automotive industry is very reliant on vacuum forming to produce a wide range of vehicle parts. Vacuum forming is especially valuable to this industry as it produces lightweight, durable components at a low cost. Vacuum formed plastics remain very popular in the automotive industry as it continues to move away from heavier and more expensive steel or aluminium. Some of the most common vacuum formed products in the automotive industry include:
- Headlight Covers: Headlight covers are created on a massive scale by vacuum forming transparent and tinted plastics. Production on this scale means headlight covers can be replaced easily.
- Interior Components: Vacuum formed plastics are often used in vehicle interiors as they allow for easy technological integration. For example, most dashboards are made from vacuum formed plastic.
- Bumpers: Many cars feature plastic or part-plastic bumpers as a cost-effective alternative to steel or aluminium.
Electronic Products
Vacuum forming can be found all over the electronics industry, and vacuum formed plastics are prevalent in many of the electronic devices we use every day. The plastic’s lightweight but durable properties make it the perfect protective shell for electronic devices. These are some of the most common uses for thermoformed plastics in the electronics industry:
- Remote Controls: Almost all remote controls feature a protective casing made from vacuum formed plastics. The hollow interior allows plenty of space for the wiring and circuit board within the device.
- Remote Controls: Almost all remote controls feature a protective casing made from vacuum formed plastics. The hollow interior allows plenty of space for the wiring and circuit board within the device.
- Television Casings: Televisions began to be made significantly with plastic around the time LCD technology started becoming widely adopted in the late 1980s and early 1990s. Since then, the plastic casings have gotten thinner and sleeker.
Household Products
Vacuum forming has long been used for household products due to its affordability. Not only are they low in cost, but they’re also child-friendly as they don’t crack or shatter like glass and ceramics. Some common household items made from vacuum formed plastics include:
- Refrigeration Components: Many of the most common components in fridges and freezers are made from vacuum formed plastics. This includes shelves, freezer trays, and door casings. Most vacuum formed plastics can withstand very cold temperatures, making them the ideal choice for fridges and freezers.
- Plastic Cooking Utensils: Plastics used for cooking utensils have an extremely high melting point and are very bad conductors of heat, making them ideal for spatulas, ladles, tongs and other kitchen tools. Plastics like polypropylene also won’t break down when exposed to acids and detergents.
- Tupperware: For similar reasons to those outlined above, most tupperware is made from vacuum formed plastics. It’s highly functional and lightweight, making it the perfect solution for food storage.
Medical And Pharmaceutical Products
The medical and pharmaceutical industries use vacuum formed plastics for a number of sterile, single-use products and durable equipment. The vacuum forming process allows for maximum precision while keeping costs low- an essential balance for the medical industry.
- Disposable Medical Equipment: Thin plastic sheets can be vacuum-formed to create disposable medical equipment like masks and gloves. These plastics are easily recycled, making them ideal for single-use products.
- Medical Trays And Containers: Vacuum formed plastics are easily sterilised and lightweight, making them the ideal material for medical trays and containers. These plastics can be cleaned easily, which is a must in the medical industry.
- Sterile Packaging: Medical tools need to be transported in sterile packaging, and vacuum formed plastics are the ideal solution. Super-thin sheets of plastic can be sealed to protect medical tools but also opened and discarded for quick and easy access.
Agriculture Products
Vacuum formed plastics play a crucial role in farming and help keep food costs down. They’re highly durable and weather-resistant, meaning they can withstand the heavy use associated with the agriculture industry. These are some of the most common examples:
- Seed Trays: Large-scale seed trays are used to hold the soil in place so the seeds can germinate and grow into healthy plants. These trays are made from thin, vacuum formed plastics as they won’t degrade in the time it takes for the produce to develop.
- Greenhouses: Today, most greenhouses are made from acrylic or polycarbonate, not glass. These plastic alternatives are stronger, more cost-effective, and provide better light transmission than real glass, meaning healthier plants.
- Agricultural Vehicles: Many components of farm vehicles, like the seats and bumpers, are made from vacuum formed plastics. These vehicles undergo very heavy use, so materials that can be replaced cheaply are necessary.
- Food Packaging: Once food products have left the farm, they’re usually packaged in thin vacuum formed plastics to prevent bacteria or other external issues impacting the quality of the food.
Create Your Own Vacuum Formed Products
It’s clear that vacuum formed plastics are all around us. From medical equipment to TV remotes, these versatile plastics have made their way into every aspect of our lives. All of these products start their lifecycle as a sheet of plastic before being moulded in a vacuum forming machine. So, if you’re looking to tap into the massive potential of vacuum formed plastics, you’ll need top-quality machinery to get you started. At O’Leary Engineering, we’ve been supplying market-leading vacuum forming and thermoforming machines for over 50 years. Get in touch today and find out which of our products best suits your business needs.