Vacuum forming is a great way to create custom molds, packaging, and end-use products - in this article, we'll break down the different types of vacuum forming and what they can be used for. 

What is a Vacuum Former?

A vacuum former is a device that uses vacuum pressure to shape thin sheets of plastic material into a specific form or shape. The process typically involves heating a sheet of plastic until it becomes soft and pliable, and then placing it over a mold or template. The vacuum former then uses a vacuum pump to remove the air from the space between the plastic and the mold, creating a tight fit that conforms to the shape of the mold. The plastic is then allowed to cool and harden into the desired shape.

The Mayku FormBox is a desktop vacuum former that
The Mayku FormBox is a desktop vacuum former that's excellent for at-home, small business, or education use.

What is a Thermoformer?

A thermoformer, also known as a thermal forming machine, is a device that uses heat and pressure to form plastic sheets into specific shapes. Unlike vacuum forming, which relies on vacuum pressure alone to shape the plastic, thermoforming typically involves heating the plastic sheet until it becomes pliable, and then pressing it onto a mold or template using a combination of heat and pressure. The plastic is then allowed to cool and harden into the desired shape.

What is a Pressure Former?

The pressure forming process is similar to vacuum forming, but instead of relying solely on a vacuum to pull the heated plastic sheet onto the mold, pressure is applied from above to push the sheet down onto the mold. This pressure can be applied using a pneumatic press or by using a male mold that pushes the sheet down onto a female mold.

The Mayku Multiplier is a desktop, professional-grade pressure former.
The Mayku Multiplier is a desktop, professional-grade pressure former.

What are Common Materials Used in Vacuum Forming?

While there are a wide variety of plastic sheets available for desktop thermoforming (some well-suited for certain projects over others), it's more fun to talk about what kinds of materials you can put into the molds that you've created. Here are some common materials that people use for vacuum forming projects: 

  1. Concrete
  2. Wax
  3. Silicone rubbers
  4. Epoxy resin
  5. Polyurethane resin
  6. Plaster of Paris
  7. Chocolate
  8. Soap
  9. Water - custom ice cubes
  10. Jesmonite

The choice of material will depend on the specific needs of the project, such as the desired finish, durability, or flexibility of the final product. Ideally though, the material moves from liquid to solid after setting, making it much easier to remove from the mold. 

You can use a wide variety of materials to pour into your custom molds, including concrete! (Photo courtesy of Mayku)
You can use a wide variety of materials to pour into your custom molds, including concrete! (Photo courtesy of Mayku)

What Can You Use Vacuum Forming For?

Vacuum forming is a versatile process that is used in a ton of different ways. Individuals, small businesses, and major production/manufacturing facilities use vacuum forming on a daily basis. 

Here are some cool ways that people/businesses are using vacuum forming: 

1. Make Custom Molds for Food and Chocolate with Vacuum Forming

Creating both custom molds for chocolate and custom packaging is very common in the chocolate industry. Paul A. Young is an award-winning chocolatier who uses vacuum formers like the Mayku Formbox for his business. Fun fact - this is also super fun to do just at home as a hobby! 

Many chocolate makers use vacuum forming to make both molds for chocolates and custom packaging.
Many chocolate makers use vacuum forming to make both molds for chocolates and custom packaging. (Photo courtesy of Mayku)

2. Start Your Small Business

You can create a variety of end-use products - from custom soap, to candles, to homeware products - with the aid of vacuum formers like the Mayku Formbox and Multiplier. Just as Ewa Lefmann, who creates stunning modern homeware products like mirrors and stash trays. You can find more of Ewa's work on Instagram @studioevka. 

Create custom homeware products like Ewa Lefmann does for her homeware brand, Evka Home. (Photo courtesy of @studioevka and Mayku)
Create custom homeware products like Ewa Lefmann does for her homeware brand, Evka Home. (Photo courtesy of @studioevka and Mayku)

3. Prototype Products and Packaging Quickly with Pressure Forming

Companies utilize pressure formers like the Mayku Multiplier to save time and money. Less outsourcing and faster design iteration help brands like Beta Design Office prototype products faster. 

Pressure forming is a great way to prototype products and packaging. (Photo courtesy of Beta Design Office and Mayku)
Pressure forming is a great way to prototype products and packaging. (Photo courtesy of Beta Design Office and Mayku)

Find a variety of desktop vacuum formers at MatterHackers here.