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Make a Plastic Vacuum Molder using parts around the house.
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NOTE--This article was originally posted at SheekGeek. This is my first tutorial or instructable. www.ThermalTrendsPlastic.com
Plastic vacuum formers are an important part of prototyping. If you need a nice plastic robot body, or
custom case for a project you are doing, get your tools, 'cause this one's easy to build and fun to play
Related
with.
Rapid Technique: Preparing
The vacuum former uses a simple concept. They use the power of a vacuum to suck gooey plastic sheets Plastic #11;CNC Milling
very tightly around an object you place in them, making a 3D copy of pretty much what ever you want. "Blanks" for Parts Used
in#11;Protot…
by siderits
Plastic vacuum formers are usually big, expensive machines; however we don't always need to make
huge pieces for our projects, so these machines would be pointless to have, or at least that's what I tell Make a good, cheap,
myself so I won't want one ;) upgradeable sheet plastic
vacuum former
by drcrash
Our molder will have a good size for most projects that you probably deal with. If you get confused or just
want to see what I am talking about, watch this short clip showing the video of a vacuum form I made.
how to make an ear v.3
by enVide neFelibata
-A hollow cavity, like a strong, airtight box. This is to get the same approximate suction on all parts of the
top
Building a Toy Story vs.
Child's Play Halloween
-A vacuum cleaner (shop vacs are a pretty good choice because they have a lot of suction, but a normal
Custom made; shaped,
vacuum cleaner will work too.) This is the source of the suction. flavoured and coloured
chocolates.
-Two frames to hold sheets of plastic. This can be two picture frames, or something made of Popsicle by thydzik
sticks.
The first plastic molder I made was a test run of what I wanted, but it worked so great, that I usually use it More Related
for all the small parts I make. I will first tell you how to make one of these, you don't have to build it, but it
will show the concepts of how and why the machine works. The bigger machine is described later in this
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
275,060
Parts list for very small plastic molder: views
1 - Plastic peanut butter jar or similar. (Don't use glass, you'll need to cut it some.)
14 Author: sheekgeek
Followers Published: Feb 23, 2007
1 -2 liter coke bottle or similar.
Follow License:
Guides
Tools needed:
-- A good sharp cutting knife or razor (be careful don't cut yourself!)
--An electric drill with a small drill bit, a Dremel works nice with the standard 1/8 inch drill bit.
First, drill a bunch of little holes in the lid of the jar, spaced about 1/4 of an inch apart. Try to evenly space ARTS AND CRAFTS
them in a grid pattern. This will become our "workspace." GUIDE
Step 3 Prepare the Jar
EASTER
Second, cut a hole in the side of the peanut butter jar just large enough that little more than the tip of the
2 liter bottle top will fit through it.
More Guides
Then use the knife to cut the top off of the coke bottle, Put the top of the bottle through the hole in the jar
from the inside like this:
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
Now saran wrap and tape the whole assembly. (Make sure to get saran wrap in the threads of the screw
top of the jar.)
Put the lid back on the jar. The whole thing should be air tight except for the holes in the top. For plastic, I
use the sides of one-gallon water jugs or milk jugs. Cut off the sides of the jugs and clamp them (or hold
them somehow) between the two frames.
Step 7 Use it
Select what ever object you want to copy. Some tips on selecting objects:
-- Make sure that the object is not tapered on the bottom. This will make it impossible to get out of the
plastic shell we are making.
-- Make sure that the entire object fits on the workspace leaving plenty of holes around the edges.
--Make sure the object can stand the pressure and heat of the process, otherwise they will deform or
melt.
--Make sure the object is not too tall, if it is too tall, the plastic will be stretched too much, and become too
thin to work with.
Now place the selected object onto the workspace and put a spacer under the object so that the final
product will look better. Use the vacuum cleaner's attachment hose to connect the vacuum cleaner to the
2 liter bottle top on the vacuum former. Heat up the plastic between the frames with a heat gun or hold
the plastic over the burner of an electric oven until the plastic starts to get gooey and sag in the middle.
HDPE plastic will turn from white to clear when its warm, this is normal. DO NOT use a gas burner; it will
catch the plastic on fire which is not good.
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
Once the plastic is good and saggy, slowly place it over the object. The plastic will stretch over the object.
Try to get a good seal all around the object, it should be air tight to get maximum suction. Once the
airtight seal is formed, turn on the vacuum. Don't keep it on, just hit it with a good second-long burst.
The plastic will suck tight to the object and the workspace. If when you turn off the vacuum cleaner, the
plastic is still gooey enough to try to come up slightly, hit it again with another burst from the vacuum
cleaner. It should be done by that point. Hold it steady as the plastic totally hardens. When it is done,
leave it alone for a little while so the plastic can cool off.
Once the plastic is cooled, take the frames off the plastic. It should look something like this:
Cut the extra off and put it in the recycling bin and you are done!
Get some more practice with it; see what you can do and how it all works.
If you would like to make a bigger vacuum forming machine, you will need the following:
--One 5 gallon plastic trash can with an approximately 8x12 inch rectangular top.
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
Do basically the same thing as above on a larger scale. Drill a grid pattern of small holes in the baking
sheet. Cut the bottom off the 20 ounce coke bottle. Cut a hole just large enough for the 20 ounce bottle
near the bottom of the trash can. (Now here's where I have had a bit of a problem, you may need to
reinforce or brace the inside of the trash can and/or the bottle with some wood or something before you
go on, otherwise, it'll collapse under the vacuum some. It hasn't caused too many problems for me, but it
could for you.)
Put the 20 ounce bottle in the hole in the trash can and caulk the seal between them pretty strongly to
make sure that it is air tight. Then turn the baking sheet up side down and caulk it to the trash can. Let
dry, and you are done.
When you are finished with the plastic mold, you can fill it with either fiberglass resin or Alumilite to get an
exact copy of your original object.
I don't what they use to add the coloring... not sure if it would cause any problems. Anyways,
just a suggestion because they're cheap and easy to find. The attached image shows what
I'm referring too. They're 0.2" thick: 1. Flexible Cutting Board 2 Pack (12" x 18") - $3.99 on
webstaurantstore.
2. MIU Flexible Cutting Board, Set of 5 (11"x15") - $9.99 on Amazon.
I was also thinking of laminating sheets, but I think they'd be too thin and stretch to the point
of tearing. I'll let you know the results I get if I try either of them. Great Instructions though,
thanks!
Reply
kriogenic says:
Wow, thanks for this instructable, I didn't realize the concept of these was so simple. I made the small
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
one and it worked a treat. I then made one out of an old oven emptied out welded Oct 15, 2010.
airtight 7:07 AM
with the
glass replaced with plexiglass. as the vacuum source, a garden blower\vacuum, I made a frame for
this to go on top with clamps.
to make things a little easier for the heat source, I got one of those portable bbq stoves. I then hung it
upside down above my frame unit and fixed a sheet of aluminium just below that with a 2cm gap from
the stove and a 2mm space from where my clips and frame is.
Finally clamp my sheet up top, turn on heat source. heats up aluminium and with the small gap it
heats up most of the plastic.
and your good to go, I've made things up to 70cmW x 70cmL x 30cmH with this setup... though the
oven could be replaced with anything its all i had and i had the welder rented the day before for
something else anyway.
Reply
XOIIO says:
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How to Make Your Own Prototypes : How to make your own Plastic Vacuum Former 2/2/12 2:18 PM
How did you make the popsicle frame so that it was even? Apr 25, 2010. 9:20 PM
Reply
28
You can use any kind of frame for this though, Dollar store picture frames are another idea
I had.
Goog luck!
Reply
servion says:
thats right. and you avoir collapsing problems with the bottle...
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The inner layer melts at a much lower temperature than the outer, so that the inner layer
sticks to the paper being laminated, while the outer layer is unaffected by the heat.
Reply
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