VACUUM FORMING

Vacuum Thermoforming Capability

Vacuum thermoforming (vacuum forming) is a manufacturing process in which a heated thermoplastic sheet is formed over a mould using vacuum pressure. It enables efficient production of lightweight, durable components with complex geometries and excellent surface finish.

Aero Services applies vacuum forming across aerospace, rail, automotive, defence, and industrial applications.

 

Materials & Thickness Range

We process a wide range of thermoplastic materials with sheet thicknesses in the range:

0.7 mm ≤ t ≤ 6.4 mm

Supported materials include:

  • ABS
  • Acrylic
  • PVC / Acrylic
  • HIPS / PST
  • Polycarbonate
  • PETG
  • HDPE

We offer multiple material options that comply with UL94, FAR 25.853, and DIN 5510-2 flammability requirements, allowing components to be tailored for safety-critical and public-transport applications.

 

Typical Vacuum Formed Products

Our vacuum forming capability supports a wide range of products, including:

  • Dashboards
  • Door covers
  • Wheel arches
  • Ducting
  • Electronic enclosures, covers, and radomes
  • Signage
  • Point-of-sale components

 

Vacuum Forming Capability & Capacity

Aero Services operates five vacuum forming machines, enabling the manufacture of components ranging from very small parts to large-format panels.

  • Minimum component size: approximately 60 × 60 mm
  • Maximum component size: up to 2100 × 1250 mm
  • Typical cycle times (excluding trimming): 3 to 10 minutes, depending on component size, material type, and thickness

With integrated robotic trimming, Aero Services can produce well over 500 finished components per day, trimmed to drawing across a wide range of sizes. The process is inherently scalable to support higher production volumes where required.

 

Advantages of Vacuum Forming

Vacuum forming offers several advantages over alternative manufacturing processes:

  • Significantly lower tooling and setup costs
  • Ability to produce complex three-dimensional shapes
  • Faster production rates compared to FRP / GRP processes
  • Wide material selection to suit varying operating environments
  • Cost-effective manufacture of large components compared to injection moulding
  • Easier and lower-cost tooling modifications compared to other forming processes

 

Integrated Manufacturing Approach

Vacuum forming at Aero Services is supported by in-house design, tooling, trimming, and finishing capabilities, enabling efficient development from prototype through to production.