Excelite

VACUUM THERMOFORMING

Manufacturing in China,  Competitive price, wide range of material 

Excelite Vacuum Thermoforming Service

Vacuum forming turn flat plastic sheets into 3D products.

Vacuum thermoforming is a plastic manufacturing process that involves heating a plastic sheet until it becomes pliable, then using a vacuum to pull the softened sheet tightly against a mold. As the plastic cools, it hardens into the shape of the mold, creating a durable and detailed part. This method is widely used for producing large, lightweight parts with precise details and is ideal for applications such as packaging, automotive parts, signs, and various consumer products.

Based in China, Excelite’s plastic fabrication center specializes in various types of plastic thermoforming, including vacuum thermoforming for large, heavy-gauge polycarbonate and acrylic sheets. We offer top-quality manufacturing for a range of industries worldwide.

With over 15 years of experience, Excelite has been vacuum thermoforming polycarbonate, acrylic, and other clear plastics. We export our products globally, serving countries such as the USA, Mexico, Chile, Peru, Colombia, UAE, Singapore, and Australia.

Our capabilities

Benifits of vacuum forming

Benefits of Vacuum Forming:

  1. Versatile Material Options: Vacuum-formed parts can be created using a wide variety of base materials, like polycarbonate sheet, Acrylic sheetHDPE, ABS, PE, PETG, finishes, colors, and textures, offering endless customization possibilities.

  2. Built-in Design Features: Logos, model numbers, and other design elements can be molded directly into the surface of the part. This eliminates the need for additional labor and ensures these features are permanent.

  3. Durable and Flexible: Thermoplastic used in vacuum forming are highly resilient. The resulting parts are resistant to rust, rot, and chipping, while also being able to withstand significant impact and return to their original shape.

  4. Lightweight: Vacuum-formed parts can be produced with thin walls from low-density plastic, resulting in durable yet lightweight products. They are often lighter yet just as strong, or stronger, than molded fiberglass or sheet metal.

  5. Cost-Effective: Vacuum-formed plastic parts are typically much more affordable compared to sheet metal or hand-laid fiberglass. Additionally, the tooling for vacuum forming is far less expensive than that for other plastic processes such as injection molding, rotational molding, or blow molding.

  6. Quick Time-to-Market: Tooling for vacuum-formed parts can be designed, engineered, and fabricated within weeks, allowing for much faster production and delivery compared to other manufacturing methods.

  7. Design Flexibility: The tooling used for vacuum forming can be easily and economically modified, enabling manufacturers to create different versions of a part with minimal adjustments.

  8. Seamless Construction: Vacuum-formed parts, panels, and housings are made from a single, seamless sheet of plastic, providing a clean and aesthetically pleasing result, custom-tailored to the exact dimensions, finish, and texture required.

Disadvantages of Vacuum Thermoforming

  • Only one part or product can be produced at a time, making it more suitable for small-scale production.
  • Clear plastic used in vacuum forming may display debris or imperfections from the mold.
  • Excess moisture in the material can lead to unwanted bubbles during forming.
  • Thick plastic sheets may warp during vacuuming if not carefully stretched.
  • Uneven thickness can occur, especially in deeper parts.

Vacuum forming plastics

polycarbonate sheets

Polycarbonate Sheet

As a clear plastic sheet, Polycarbonate sheet is one of the best plastic for thermoforming

Hard Coated Acrylic Sheet

Acrylic Sheet

Acrylic sheet can be formed into almost any shape, like Large Plastic Domes, Acrylic dome, Acrylic sphere, etc.

ABS Sheet

ABS

ABS is an opaque thermoplastic polymer that is commonly used in both thermoforming and injection molding manufacturing. 

Vaccum Thermoforming Post-Processing
caravan window

Assembly and Fabrication

acrylic silk screen printing

Screen Printing and Hot Stamping

Considerations when designing vacuum thermoformed parts

When designing thermoformed parts, there are three major considerations:

  1. Material Selection: Choosing the right thermoplastic material is critical based on the part’s requirements, such as durability, flexibility, impact resistance, and environmental factors like UV exposure or chemical resistance.

  2. Tooling and Mold Design: The design of the mold is essential for achieving the desired shape and detail of the part. Factors such as draft angles, undercuts, and material flow must be considered to ensure proper formability and ease of release from the mold.

  3. Wall Thickness and Uniformity: Maintaining consistent wall thickness throughout the part is important for structural integrity and functionality. Uneven thickness can lead to weak points in the part, affecting its strength and durability.

Vacuum Forming process
Vacuum Thermoforming Case Study
Vacuum forming signboard

Vacuum forming Signboard

Vacuum Formed Lightboxes, LED Vacuum Formed Sign, Vacuum Forming Signs, Outdoor LED Vacuum Formed Sign

Large size Clear polycarbonate glamping domes, size up to 7m diameter,  vacuum formed polycarbonate panels

Vacuum formed polycarbonate luggage

Polycarbonate luggage, Hard Shell Luggage, Recycled Polycarbonate Luggage, polycarbonate suitcase

Vacuum formed polycarbonate Skylight

Polycarbonate Skylight

Prismatic Skylight, Vacuum formed Polycarbonate skylight, Acrylic skylight, Skylight Diffuser Replacement

Vacuum formed machine guard

medical equipment, machine guard, Vacuum Forming for Medical Devices, Medical Plastic Vacuum Forming

heat bending polycarbonate

Industrial equipment

Incorporated in machinery parts, fixtures, and toolings, such as jigs and custom components for manufacturing processes.

FAQ

  • Cost-Effective: Compared to other plastic forming processes like injection molding, vacuum forming requires lower-cost tooling and setup, making it more affordable for small to medium production runs.

  • Quick Turnaround: Tooling can be designed and fabricated relatively quickly, allowing for faster production and shorter time-to-market, especially for prototypes and custom designs.

  • Versatile Material Options: A wide range of thermoplastics can be used, including polycarbonate, acrylic, ABS, and more, making it suitable for various applications.

  • Scalable: While ideal for small to medium-scale production, vacuum forming can also handle larger parts, such as panels, housings, and enclosures.

  • Design Flexibility: Vacuum forming offers flexibility in design, enabling the production of parts in different shapes, textures, and finishes. It can also incorporate design features like logos or text directly into the mold.

  • Lightweight and Durable Parts: Vacuum-formed parts are lightweight but durable, making them ideal for applications in industries such as automotive, aerospace, and packaging.

  • Customization: It allows for easy modifications to the molds, enabling quick adjustments to designs without significant costs.

  • Application: Vacuum forming is ideal for creating large, thin parts with simple shapes. If your design is complex, consider alternative manufacturing methods.

  • Material Selection: Vacuum forming is compatible with various thermoplastics, such as ABS, PVC, and acrylic. Select a material that fits your specific application needs.

  • Cost: Vacuum forming is cost-effective for producing large quantities of thin parts. For smaller runs, other processes may offer better cost efficiency.

  • Turnaround Time: While vacuum forming can quickly produce parts, the time required to create the mold may extend the overall lead time.

  • Design Considerations: Vacuum forming requires a mold, so be sure to account for the cost and time involved in designing and producing the mold.

Excelite’s plastic fabrication center is located in Suzhou, China, supplying a wide range of polycarbonate sheets and offering plastic fabrication services globally, including to the USA, Mexico, Chile, UAE, France, Germany, and Singapore. We also have an overseas branch in Victoria, Australia, and provide polycarbonate sheets with nationwide shipping across the country.

People often ask which plastic is best for vacuum forming. Typically, vacuum forming uses thermoplastics, which become flexible at certain temperatures and solidify once cooled. One commonly used material is high-impact polystyrene (HIPS), known for its flexibility and ability to be molded into almost any shape.

Polycarbonate (PC) is another popular choice for vacuum forming. It’s extremely tough and resistant to flames, chemicals, and water, making it ideal for medical equipment and food manufacturing machinery. It’s also easy to mold, trim, and fabricate.

Acrylic (PMMA) is another widely used plastic for vacuum forming and thermoforming due to its versatility and ease of use.

Lead times are 2 to 3 weeks for prototypes and 4 weeks for production runs. Some special urgent orders can be discussed beforehand.

One of the key advantages of vacuum forming is its cost-effectiveness. While the initial machinery investment may be significant, it is highly versatile and can produce a wide variety of products. Additionally, once molds are made, they can be reused repeatedly for mass production, making vacuum forming one of the most affordable methods of plastic fabrication.

Pressure forming provides a contrast to vacuum forming. The use of high pressure to push and pull the plastic tightly against the mold allows for greater precision, detail, and sharpness, while still being suitable for forming large plastic parts with ease.

Why Excelite?

With over 15 years of polycarbonate fabrication and machining experience, Excelite specializes in the fabrication of polycarbonate and acrylic sheet products, ensuring top-notch quality and precision. We are committed to providing the best manufacturing solutions tailored to your unique requirements. 

Whether you have a detailed drawing or just an idea, our team of professionals is ready to turn your vision into reality. Enjoy the benefits of our services, including:

  • In-house Design & Tooling
  • Exceptional Accuracy (+/- 0.005″ Tolerances)
  • Comprehensive OEM & ODM Services
  • ISO 9001:2008 Certification
  • Direct Manufacturer Advantage

We invite you to partner with us and experience a seamless, efficient, and quality-driven production process.

 
 
TAILORED POLYCARBONATE SOLUTION

Get a Quote Today

Looking to transform your vision into a tangible product? 

At Excelite Plastics, we understand that every project is unique.

sales@exceliteplas.com

+8613913571706(China)    

+61452 396 680(Australia)

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