Vac Forming (Thermoforming)

One of our specialties is custom vacuum forming, which allows your designers to specify plastic parts that meet high quality standards, even if you do not have the volumes that justify expensive injection molding. Our past projects have included building parts for an Orlando theme park’s rides, “boutique” parts for medical equipment and protective covers for a mobile electronics firm.
 
Basically the general process of vacuum forming is to make a mold, place a sheet of plastic over it, heat it up, and suck it over or into the mold. And you’re done!

While some people make this sound easy, meeting high quality standards is not as simple as it sounds

Our quality thermoforming process starts with our investment in software and our own CNC machines to build your mold “tool.” Our skill at making these “tools” ensures the finished parts will meet your specific demands. We can work from your sketches or CAD files. Today’s computers are so amazing, we can actually use a 3D scanner to capture the data needed to replicate an actual part you want duplicated.

After the process is completed on one our vac forming machines, parts often require holes or slots cut as well as finish trimming, routing, drilling, and removing any burs. As a result, we often spend just as much engineering attention on trimming your part as we do when we are building your mold. By relying on 5-axis CNC machines, driven by CAMWorks or Mastercam software we can ensure accurate repeatability

PROTOTYPES, "BOUTIQUE" ITEMS & PRODUCTION RUNS We have designed our facilities and developed skills to maximize flexibility. As a result, we can match our services to your needs, whether you only need support developing a unique component or completing multiple production runs.

Prototypes - If you are looking to take your product, idea or invention to the next level, we can help you turn your thoughts into reality. We have worked with design teams at major firms to build full-scale prototypes to gauge a new product’s form, fit and function. A professionally manufactured prototype by NCAD can also help inventors sell an idea to an investor or manufacturer.

“Boutique” Items - We’ve borrowed a term from musical instrument makers and now call many of the products we manufacture “boutique” items—high end, sometimes hand crafted products made in small numbers. We enjoy being involved in unique products as well as getting the chance to combine our craftsmanship with the state-of-the-art technology required to build these parts.

Production Runs - In today’s competitive environment, getting products to market fast and keeping inventory costs under control are two of the keys to a company’s success. At NCAD, we can help you meet these challenges. For example, we have invested in leading edge software that tracks both our projects requirements and our machines capacities. By maintaining accurate work flows, having the flexibility of using one of our many machines and being willing to finish, assemble and package your parts, you can rest comfortably knowing we will get your goods out the door on time or before. All at a long-term cost savings to you.

Advantages Include

Short lead times Quick, low-cost tool building Economical for small to medium production runs Efficient prototyping Choice of finishes Ability to handle parts up to 3 ft by 5 ft No need for painting; the color and texture can be formed into the part

VAC FORMING PROCESS
printable version (PDF)

Original part design
 

Vac-form tool design
(completed in-house)


CNC cut male form tool 
(completed in-house)


Vac-form tool complete and ready to run

Stretch Heated Sheet Over Form Tool


Evacuate Air Between Plastic and Form Tool
 

5-Axis CNC Trimming
 

Completed part