Vacuum and pressure forming technology: Achieving large-scale molding and cost reduction!
Vacuum and pressure forming technology
Ideal for cost reduction! Easy to change cut dimensions and hole processing! Large-scale molding is possible!
Vacuum forming is a molding method that applies atmospheric pressure to sheet (resin sheet) molding. The sheet (resin sheet) is softened using a heater, and by creating a vacuum in the space (gap) between the softened sheet (resin sheet) and the raised molding die, the sheet (resin sheet) is made to adhere closely to the mold, resulting in the desired shape. In vacuum forming, the internal dimensions (inner dimensions) of the basic molded product serve as the reference dimensions, and molding is done using a male mold (positive mold). In this case, there are no mold marks on the product surface (outside of the mold). However, the product's form will have a softer and more textured finish due to the thickness of the sheet. In contrast, if a sharper molding expression similar to injection molding is desired, pressure forming, which applies a pressure greater than atmospheric pressure, is effective. Molding is done using a female mold (negative mold), allowing for accurate external dimensions (outer dimensions) of the molded product. However, in this case, the mold will touch the product surface, so mold marks cannot be avoided. We address mold marks with treatments such as blasting. Additionally, undercuts can also be molded.
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basic information
The main types of molds include "wood molds," "chemical wood molds (composite wood molds)," "resin molds," and "metal molds" (pressure forming requires metal molds). Since the structure of the molds is simple and can be formed using only one side, either convex (male mold) or concave (female mold), it is optimal for cost reduction. Compared to injection molding, the mold costs are only a fraction of the price, making it suitable for small lot production. This reduces initial costs and often results in lower total costs. Trimming after molding is done using NC machines, allowing for easy adjustments to cutting dimensions and hole processing through processing programs without changing the mold, as long as the shape itself is maintained. Large-scale molding is possible; however, care must be taken due to height restrictions on the molded products. Disadvantages include the need for trimming unnecessary parts after molding, which leads to significant material waste. Additionally, ribs cannot be added to the mold contact surface, which may necessitate secondary processing such as adhesion. The thickness of the product can vary in certain areas (areas where the original board has stretched become thinner), making thickness adjustment difficult. Since only one side of the product touches the mold, dimensional accuracy is based on the mold contact surface.
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Applications/Examples of results
Plastic fixtures and displays Excellent compatibility with LED lighting Many other applications
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Company information
Founded over 60 years ago, Shinshi Co., Ltd. is a pioneer in plastic (resin) sheet processing, possessing the technology to consistently perform bending, cutting, grinding, adhering, and polishing. It is one of the few companies in the acrylic processing industry that has both molding technology and cutting and bonding technology, collaborating from rough sketches before they are drafted. The range of services includes large molded products (one of the largest in the industry for vacuum forming, press forming, and air pressure forming) to secondary processing (cutting, bonding, surface treatment, etc.). In the aquarium industry, since the use of acrylic panels, we have collaborated with Mitsubishi Rayon (Hishiko) for many years to produce acrylic panels for aquariums both domestically and globally, accumulating a wealth of achievements. We have also been manufacturing three-dimensional molded signs and components for amusement devices by combining screen printing and molding for many years. Other products include medical devices, electronic equipment, construction materials, objects, and spatial displays. For inquiries regarding prototyping, small lots, mass production, short delivery times, and low costs, please consult Shinshi, which has abundant processing technology.