Things to Bring
- Laptop (optional)
- Notebook and pen
- Any existing moulds, prototypes, or project ideas you'd like to discuss
No prior experience required.
Ever wondered how plastic packaging, cosplay armour, stormtrooper helmets, chocolate moulds, prop parts, and product trays are made?
Our Vacuum Forming Workshop teaches the fundamentals of thermoforming plastic sheets over custom moulds to create professional-looking parts quickly and cost-effectively.
Whether you're a maker, cosplayer, designer, educator, engineer, or small business owner, vacuum forming is a valuable manufacturing process that can produce lightweight, durable parts in minutes.
What You'll Learn
Introduction to Vacuum Forming
- What vacuum forming is
- How the process works
- Common applications and industries
- Material selection and capabilities
Mould Design
- Positive vs negative moulds
- Designing moulds for successful forming
- Draft angles and release considerations
- Surface finish requirements
- Multi-part mould concepts
Materials & Plastics
- PETG
- HIPS
- ABS
- Polycarbonate
- Specialty plastics
- Material thickness selection
Operating a Vacuum Former
- Machine setup
- Heating procedures
- Material preparation
- Forming techniques
- Cooling procedures
- Safe operation
Troubleshooting
- Webbing
- Thin spots
- Incomplete forming
- Material tearing
- Surface defects
- Poor detail reproduction
Hands-On Activities
Participants will:
- Create vacuum formed parts
- Learn mould preparation techniques
- Form plastic over various mould designs
- Evaluate finished parts
- Learn best practices for repeatable results
Applications Covered
- Cosplay armour and props
- Product packaging
- Product prototyping
- RC and drone canopies
- Chocolate and casting moulds
- Display trays
- Educational projects
- Small-batch manufacturing
Who Is This Workshop For?
- Makers
- Cosplayers
- Product Designers
- Engineers
- Small Businesses
- Schools & STEM Programs
- Artists & Creators
- Anyone interested in manufacturing
By The End Of This Workshop
You'll understand how vacuum forming works, how to design successful moulds, select suitable materials, and confidently operate a vacuum forming machine to create professional-quality parts.
Learn how to turn a simple plastic sheet into a finished product in minutes with the power of vacuum forming.
