In the exciting world of plastics and 3D printing, there exist two popular methods of thermoforming: pressure forming and vacuum forming. These techniques, while seemingly similar, have distinct differences and unique advantages. This article aims to shed light on these two processes, helping you understand which one might be the best fit for your projects.

Understanding Vacuum Forming

Vacuum forming, also known as vacu-forming, is a simplified version of thermoforming. The process begins by heating a plastic sheet until it's pliable. The softened sheet is then stretched onto a single-sided mold, and a vacuum is applied, sucking the sheet into the mold. The plastic cools and hardens, taking the shape of the mold.

This method is widely used due to its cost-effectiveness and simplicity. It's ideal for creating shallow-depth items and is commonly employed in making packaging, automotive parts, and signage.

Vacuum forming
This is the Mayku Formbox, which is an affordable desktop vacuum former. 

Exploring Pressure Forming

Pressure forming, on the other hand, is a more sophisticated process. Like vacuum forming, it starts by heating a plastic sheet. However, once the sheet is draped over the mold, pressurized air is applied to the backside of the sheet, pushing it against the mold. This method allows for greater detail and a higher level of texture and design.

Pressure forming is an excellent alternative to injection molding when a more detailed, textured, or aesthetically pleasing surface is required. It's often used in medical device enclosures, equipment housings, and automotive components.

Pressure Forming
This is the Mayku Multiplier, an industrial desktop pressure former. 

Pressure Forming vs. Vacuum Forming: The Differences

  1. Detail and Texture: Pressure forming allows for a greater level of detail and texture due to the application of pressurized air. It can replicate intricate mold details, providing a high-end finish. Vacuum forming, while efficient, doesn't offer the same level of detail.

  2. Cost: Vacuum forming is generally more cost-effective, particularly for small to medium-sized production runs. Pressure forming, while potentially costlier, can be more economical than injection molding for certain applications, especially when a high degree of detail is required.

  3. Applications: The choice between pressure and vacuum forming often depends on the end-use of the product. Vacuum forming is ideal for simpler designs and shallow molds, while pressure forming is better suited for complex and detailed parts.

  4. Speed: Vacuum forming tends to be quicker due to its simplicity, making it ideal for high-volume production. Pressure forming might take longer but results in a higher-quality finish.

In conclusion, both pressure forming and vacuum forming have their place in the world of plastic fabrication and 3D printing. The choice between the two depends on your project requirements, budget, and the level of detail you desire. At MatterHackers, we're always here to help you navigate these choices and find the best solution for your needs.

Explore the Mayku Multiplier - a desktop pressure former that's capable of using tons of industrial materials and can capture details finer than a human hair! 

View all thermoforming options at MatterHackers here