Vacuum forming is one of the most versatile processes in our workshop, and one of the most underrated. A sheet of plastic is heated until pliable, then drawn down over a tool using vacuum pressure to form a precise, repeatable shape. The result is a lightweight, durable component that holds tight tolerances and takes paint, texture and finish well. We use vacuum forming across a wide range of applications. Display shells, packaging inserts, protective covers, enclosures, scenic elements, product mock-ups and structural panels. It sits alongside our CNC, laser cutting and 3D printing capabilities as a core in-house process, which means we can integrate it into complex builds without farming anything out. We work primarily with acrylic, PETG, ABS and HIPS, and we form sheets from 0.5mm to 10mm depending on the application. If you are not sure which material suits your project, we will tell you.
Tooling and Production For most vacuum forming jobs, tooling is straightforward. We machine tools in-house from MDF, resin or aluminium depending on run volume and finish requirements. Short-run and prototype tooling can be turned around quickly. Longer-run production tooling is made to last. We will advise on the right approach based on your quantities and budget. Because everything is in-house, we can move fast when a brief demands it. From tool sign-off to formed parts in days rather than weeks. We also handle trimming, drilling, finishing and assembly as part of the same job, so you receive a ready-to-use component rather than a raw formed sheet. Where We Use It Retail display components and housing. Point-of-sale shells. Packaging inserts and protective trays. Exhibition props and scenic panels. Product development mock-ups. Automotive and consumer electronics enclosures. If it is plastic, three-dimensional and needs to be consistent across multiple units, vacuum forming is almost certainly the right process.
