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In vacuum forming, or thermoforming, extruded plastic sheet is heated and formed over a cast aluminum mold to produce a part. Thermoforming is one of the most versatile and economical processes available for manufacturing returnable packaging and many other products.

As a custom Prop & Model shop we've had to develop many unique methods of production for creating affordable high value products. To this end we have worked for years to adapt the production processes of thermoforming to the "one off" needs of a shop like ours.

Below you will find some in-depth information on the process of thermoforming to help you better understand how we can create the pieces you need.

Thermoforming (or vacuum Forming) is a method of manufacturing plastic parts by preheating a flat sheet of plastic, bringing it into contact with a tool whose shape it then takes on. This can be done by vacuum, pressure, and/or direct mechanical force.

When used for production parts this process can offer tight specifications and sharp detail. With the proper finishing techniques, thermoformed parts can be comparable to injection molded pieces in quality, while costing much less.

However, in a Prop and Model shop, thermoforming is used primarily as a low-cost application for the creating multiples of a shape that may be required for a display or model. This method allows for the creation of a sculpted or modeled "Tool" that will be used to form over. The number of parts that can be formed is driven by the process used to make the tool.

Thermoforming tools can be made of any number of materials. If a job calls for just a part or two, the tool would likely be done in a high density foam. When the job calls for more then a few parts, a much higher density tooling board would be used to increase the life span of the tool. When the tool requires a great deal of detail, it's made using sculpted clay and a rubber mold is made. The tool is then cast in a filled resin that will withstand the heat created by the forming process.