Vacuum forming is a widely used plastic forming process that involves heating a sheet of plastic until it becomes pliable, then shaping it over a mould using vacuum pressure. This cost-effective and efficient method is popular across various industries, including packaging, automotive, and medical applications. However, the choice of plastic plays a crucial role in determining the quality, durability, and application of the final product.
Common Plastics Used in Vacuum Forming
High-Impact Polystyrene (HIPS)
Properties: HIPS is a lightweight, durable, and cost-effective thermoplastic. It has excellent impact resistance and is easy to form, making it a popular choice for vacuum forming applications.
Applications: Commonly used for product packaging, trays, signage, and display units. It is also suitable for prototyping due to its ease of manipulation.
Acrylonitrile Butadiene Styrene (ABS)
Properties: ABS is well-known for its strength, rigidity, and impact resistance. It also has good thermal and chemical resistance, making it highly durable.
Applications: Widely used in automotive components, consumer electronics casings, protective headgear, and industrial housings.
Polycarbonate (PC)
Properties: Polycarbonate is an extremely strong and transparent plastic with high impact resistance. It is also heat resistant and provides good dimensional stability.
Applications: Commonly found in safety equipment, machine guards, medical devices, and bullet-resistant panels.
Polyethylene Terephthalate Glycol (PETG)
Properties: PETG is a food-safe plastic with high impact resistance, excellent clarity, and chemical resistance. It is also easy to sterilise, making it ideal for applications where hygiene is essential.
Applications: Used in food packaging, medical trays, protective face shields, and point-of-sale displays.
Acrylic (Polymethyl Methacrylate – PMMA)
Properties: Acrylic is known for its excellent clarity, weather resistance, and aesthetic appeal. It is harder than some other plastics but more brittle.
Applications: Often used for signage, display cases, skylights, and retail fixtures where a glossy finish is desirable.
Polyvinyl Chloride (PVC)
Properties: PVC is a strong, durable plastic with good chemical and fire resistance. It is available in both rigid and flexible forms, making it highly versatile.
Applications: Used in medical components, protective covers, and industrial applications where chemical resistance is required.
Polyethylene (PE – LDPE and HDPE)
Properties: Polyethylene comes in two main forms: Low-Density Polyethylene (LDPE) and High-Density Polyethylene (HDPE). LDPE is more flexible, while HDPE is stronger and more rigid.
Applications: Commonly found in automotive parts, industrial storage containers, and protective equipment.
Factors to Consider When Choosing a Plastic for Vacuum Forming
- Formability: The plastic should be easy to heat and shape without excessive warping.
- Durability: The material should provide sufficient strength and impact resistance for its intended application.
- Cost-effectiveness: Budget considerations play a role in selecting the right material.
- Aesthetic Requirements: Some plastics offer better clarity, gloss, or colour options.
- Regulatory Compliance: In industries like food and healthcare, materials must meet strict regulatory standards.
Conclusion
Vacuum forming is an incredibly versatile plastic forming technique, and the choice of material is essential in achieving the desired outcome. Each plastic offers unique advantages, and selecting the right one depends on factors such as durability, cost, and application requirements.
At APT Plastics, we specialise in vacuum forming solutions, offering expert advice on material selection to ensure your products meet the highest standards. Get in touch with us today to discuss your plastic forming needs!