VACCUM FORMING
Guided by [Link] Upadhyay
AVINASH KANCHERLA
AYUSH SRIVASTAVA
244205107 244205108
Introduction / Problem Statement
Show the process and result of Vacuum forming exercise
Product idea
The initial idea for this project was to create a small, cute crayon box that would be both
functional and visually appealing. I wanted the design to be simple enough for easy
vacuum forming, but also playful to match the colorful nature of crayons. The goal was to
make a lightweight, easy-to-carry box that could neatly hold crayons, while keeping the
form soft and friendly with smooth edges and gentle curves.
Process
Making of a wooden mold
A wooden mold was made by cutting and shaping a block of wood using basic hand tools like a saw, chisel, and sandpaper. I carefully
shaped the mold to have smooth surfaces and gentle draft angles to ensure easy vacuum forming and removal of the final plastic
part.
Finishing of mold
For finishing, I carefully sanded the wooden mold using progressively finer sandpapers to achieve a smooth surface. I focused on
rounding sharp edges slightly to help with sheet forming and prevent tearing.
Vaccum forming
For vacuum forming, I heated a plastic sheet until it became soft and sagged slightly. Then, I quickly placed it over the wooden mold
and turned on the vacuum, which pulled the sheet tightly around the mold’s shape. I allowed the plastic to cool and harden before
carefully removing it from the mold. After forming, I trimmed the excess material around the edges to clean up the final product.
Making of mold wooden mold
I made the wooden mold by cutting, carving, and
sanding a block of wood, ensuring smooth
surfaces and proper draft angles for easy vacuum
forming.
Finishing of solid mold
I finished the mold by sanding it smoothly,
rounding the edges slightly, and preparing it
for easy vacuum forming.
Vaccum forming
I heated the plastic sheet, vacuum-formed it over the
wooden mold, let it cool, and trimmed the extra material to
get the final box shape.
Final Outcome
The final outcome was a cleanly formed plastic box that
captured the shape of the wooden mold well. The
surfaces were mostly smooth, and the edges were neatly
trimmed after forming. Although there were minor
imperfections due to slight draft angle issues, the overall
form was successful and demonstrated a good
understanding of the vacuum forming process.
Learnings
One mistake I made was not giving enough draft angle on the vertical sides of the mold. As a result, the plastic sheet stuck
slightly to the mold after forming, making it difficult to remove without damaging the part. I realized that even a small draft
angle is very important to allow the formed plastic to release smoothly.
From this, I learned that all vertical surfaces should have at least a slight outward slope (usually 3°–5°) to make vacuum forming
easier and to protect the final part from tearing or cracking during demolding.
Thank You!