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The economical vacuum forming process uses heat and suction to shape the plastic sheet onto the desired mold. A secondary operation is required for trimming features such as cutouts, holes, etc. The thickness of a vacuum formed part may range from .030" thin film material (packaging) up to .375" thickness for large panel covers.
 
 
  VACUUM FORMING
 
     
Vacuum Forming Advantages:
 >  Low tooling and engineering costs
>  Fast tooling and product turnaround
>  Large part production capability
>  Pre-textured sheet dispenses the need
     for paint finishing
>  Wide range of material and color choices
>  Relative low forming process forces 		  Applications:
>  Enclosures
>  Panel covers
>  Trays
>  Dividers
>  Thin gauge packaging
 >  Guards
>  Pans
>  Display cases

This process may not be suitable for parts that require:
>  Sharp and detailed formed features
>  Tight dimensional (+/-020") tolerance for formed features 
>  High volume production (over 5000pcs/year). (Except sheet fed
    packaging covers) 
>  100% uniform wall thickness control  
 

Another advantage of the vacuum forming process is the low cost of mold and tooling investment. Because of direct exposure to heat and pressure, a mold for vacuum forming can be made of softer metals and even wood or rigid foam for fast product turnaround.

Besides the low tooling costs and rapid turnaround time, the thermoforming process provides the solution for product simplification and aesthetics enhancement as seen in this picture. The bottom piece is an original fabricated part with more than a dozen separate pieces, while the top part is a single thermoformed piece with a welded drain plug added.