Things to Bring Laptop (optional) Notebook and pen Any existing moulds, prototypes, or project ideas you'd like to discuss No prior experience required. Ever wondered how plastic packaging, cosplay armour, stormtrooper helmets, chocolate moulds, prop parts, and product trays are made? Our Vacuum Forming Workshop teaches the fundamentals of thermoforming plastic sheets over custom moulds to create professional-looking parts quickly and cost-effectively. Whether you're a maker, cosplayer, designer, educator, engineer, or small business owner, vacuum forming is a valuable manufacturing process that can produce lightweight, durable parts in minutes. What You'll Learn Introduction to Vacuum Forming What vacuum forming is How the process works Common applications and industries Material selection and capabilities Mould Design Positive vs negative moulds Designing moulds for successful forming Draft angles and release considerations Surface finish requirements Multi-part mould concepts Materials & Plastics PETG HIPS ABS Polycarbonate Specialty plastics Material thickness selection Operating a Vacuum Former Machine setup Heating procedures Material preparation Forming techniques Cooling procedures Safe operation Troubleshooting Webbing Thin spots Incomplete forming Material tearing Surface defects Poor detail reproduction Hands-On Activities Participants will: Create vacuum formed parts Learn mould preparation techniques Form plastic over various mould designs Evaluate finished parts Learn best practices for repeatable results Applications Covered Cosplay armour and props Product packaging Product prototyping RC and drone canopies Chocolate and casting moulds Display trays Educational projects Small-batch manufacturing Who Is This Workshop For? Makers Cosplayers Product Designers Engineers Small Businesses Schools & STEM Programs Artists & Creators Anyone interested in manufacturing By The End Of This Workshop You'll understand how vacuum forming works, how to design successful moulds, select suitable materials, and confidently operate a vacuum forming machine to create professional-quality parts. Learn how to turn a simple plastic sheet into a finished product in minutes with the power of vacuum forming.
