3D Print Your Own Mini Vacuum Former

There are so many ways to turn stock material into a usable part. One of the most interesting is vacuum forming, because it lets you create a three-dimensional part from flat plastic sheet. It is perfect for hobbyists and makers. If you want to give it a try, you can even 3D print your own mini vacuum former.

Vacuum forming is a really simple process. You grab a sheet of thermoplastic plastic, like HIPS or ABS, heat it up so that it is almost melted, then place it on a vacuum table over a form. The vacuum creates low pressure underneath the heated plastic, causing the higher atmospheric pressure to push the plastic against the form. Once the plastic is cool enough to resist deformation, you can pull it off the vacuum table and the form. Now you have a plastic part that matches the shape of the form!

That is great for all kinds of parts, because it is quick and very economical. It also maintains the transparency of clear plastics. Those are two reasons why it is very popular among cosplayers.

The only things you need to do vacuum forming are an appropriate heat source and a vacuum table. The heat source can be an oven or a heat gun. The vacuum table is what you can print yourself.

This 100×100mm vacuum table is really just a hollow box with holes on its top and a port on the side. You attach a household vacuum cleaner to that port and it will draw air through the holes on top. There is also a frame to hold the plastic sheet as you heat it and draw it down over the form.

You can even print your own forms! There are a lot of guidelines for suitable form geometry. But generally speaking, you just want to avoid overhangs and tall protrusions, while adding draft angles like you would for an injection mold. Because this vacuum former is cheap and easy to build, you can start experimenting with minimal investment.