Vacuum forming is one of the most versatile and cost-effective plastic fabrication processes available today. From packaging trays and machine guards to automotive panels and retail displays, it’s used across countless industries thanks to its ability to produce lightweight yet durable parts quickly and efficiently. But a question we often hear is: what kind of plastic is actually used for vacuum forming?

The answer is that several types of thermoplastics are suitable for this process, each with their own unique properties and benefits. Let’s take a closer look at some of the most commonly used plastics in vacuum forming.

ABS (Acrylonitrile Butadiene Styrene)

ABS is one of the most popular materials for vacuum forming, and for good reason. It’s strong, impact-resistant, and has excellent dimensional stability. ABS sheets form well under heat and produce sharp details, making them ideal for parts that require precise shapes or surface finishes.

Products like automotive interior panels, protective housings, and cases for electronics often use ABS due to its balance of strength and ease of processing. It’s also available in various colours and textures, allowing for aesthetic flexibility in finished products.

PVC (Polyvinyl Chloride)

PVC is another widely used plastic in vacuum forming, valued for its chemical resistance, durability, and affordability. It can be produced as rigid or flexible sheets, opening up diverse applications from blister packs and clamshell packaging to industrial liners.

Rigid PVC offers excellent strength and weatherability, while flexible PVC is chosen for items needing more pliability. However, care must be taken during processing, as PVC can release fumes when heated, so proper ventilation and safety measures are essential.

Polycarbonate

Polycarbonate is a tough, high-performance thermoplastic known for its incredible impact resistance and clarity. Although it’s more expensive than some other plastics, it’s chosen for applications where strength and transparency are crucial.

Think machine guards, protective visors, and glazing panels. Polycarbonate can also withstand higher temperatures than many other plastics used in vacuum forming, making it suitable for demanding environments.

Acrylic (PMMA)

Acrylic, or polymethyl methacrylate (PMMA), is often chosen for its exceptional clarity and glossy finish, offering a glass-like aesthetic but with far less weight and greater impact resistance. It’s perfect for applications such as display cases, signage, point-of-sale stands, and lighting diffusers.

Acrylic also has excellent UV resistance, making it suitable for outdoor applications where weathering could be a concern. It’s worth noting, however, that while acrylic is tough, it’s not as impact-resistant as polycarbonate.

HIPS (High Impact Polystyrene)

High Impact Polystyrene (HIPS) is frequently used for vacuum forming where cost-efficiency is a priority. It’s easy to form, lightweight, and provides a good surface for printing and painting. HIPS is commonly used for point-of-sale displays, disposable packaging, and prototypes.

Though not as robust as materials like ABS or polycarbonate, HIPS remains popular where mechanical strength isn’t the primary concern.

Other Plastics

While the materials above are among the most common, vacuum forming can also be performed with other plastics, including PETG (Polyethylene Terephthalate Glycol), polyethene, and polypropylene, each offering specific benefits like food safety compliance, flexibility, or chemical resistance.

Choosing the Right Material

Selecting the right plastic for vacuum forming depends on several factors:

• Mechanical properties: strength, impact resistance, flexibility

• Aesthetic requirements: clarity, colour, surface finish

• Environmental factors: UV resistance, temperature tolerance, chemical exposure

• Cost considerations: budget constraints, production volumes

By understanding the properties of each material, manufacturers can ensure the finished part meets both functional and visual requirements.

In summary, vacuum forming is incredibly versatile precisely because it works with so many different plastics. Whether you’re after durability, clarity, or cost-effectiveness, there’s a material to suit virtually any project.

If you’d like advice on selecting the right plastic for your vacuum forming needs, feel free to get in touch with our team. We’re always happy to help you choose the perfect material for your application.