Custom Vacuum Forming Machine
Engineered for Performance, Built for Local Manufacturing.
A fully designed, production-ready thermoforming system, optimized for cost-efficiency and local component sourcing without compromising industrial capability.
The Core System
- 30 kW Zone Heating – 20 IR heaters in 4 independent zones for precise control
- Industrial Vacuum – Liquid-ring pump (450 L/min, -0.97 bar) for reliable, clean operation
- Automated Mold Lift – Dual hydraulic cylinders with guide rails for stable 150+ kg handling
- Production-Ready Design – Full DFM for frame, table, clamps, and concrete base mold
- Integrated Controls – Architecture for PLC, PID temperature, and safety systems
The Development Process
- Requirement & Feasibility Analysis
Defining performance targets (cycle time, vacuum level, heating power) against local market cost and part availability constraints. - Component Sourcing & Sizing
Engineering calculations for pump flow, hydraulic force, and heater power; followed by global sourcing of optimal available components (e.g., IR heaters from Shenzhen, pumps from McMaster). - Mechanical Design & DFM
Designing the structural frame, forming table with 6mm staggered vacuum holes, gas-spring clamps, and a re-usable plastic mold for the concrete base. - Integration & Documentation
Creating full assembly drawings, Bill of Materials, electrical load analysis (40 kW total), and system specifications for handoff to manufacturing.
Key Engineering Solutions
| Challenge | Our Solution | Result |
| Uniform heating on a budget | 4-zone IR heater array using sourced components. | Precise, efficient 30 kW heating. |
| Reliable vacuum with moisture | Liquid-ring pump instead of oil-sealed. | Robust -0.97 bar vacuum, low maintenance. |
| Local manufacturability | Designs optimized for standard fabrication processes. | A Package any local shop can build. |
| Safe heavy mold handling | Dual guided hydraulic cylinders. | Stable, controlled lifting. |
The Outcome
A complete machine design, ready for fabrication.
- Full Design Package
- Sourced BOM
- Manufacturing Drawings
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