Vacuum Forming

Industry Uses
Dental, aerospace, special effects, military, Holster Making, Knife Sheath Forming, Hobbyists, Cosplay, Costume Makers, Orthotics, small prototyping and many other types of thermoforming.

Vacuum Forming Machines Available
The available mechanical engineering vacuum former is located in the Metrology Lab (Room 123) inside the Gauss Johnson Engineering Lab. The sign up process to use these machines is based on a first come first serve basis. For more information on how to use these machines find a graduate student and/or go to the IEW office (GJ 113). {|
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Included Parts

 * HD Press 2424
 * 3 CFM Single Stage Vacuum Pump with check valve
 * 1 Extra - High Temp Heavy Duty Membrane
 * Neodymium Magnets (+ 5 extras)
 * Heatsink board
 * Premium Quality Liquid Filled Vacuum Gauge
 * ON-OFF Valve
 * Vacuum Release Vent
 * 1/2” Easy Connect NPT Elbow
 * 3/8” Easy Connect NPT Elbow
 * 3ft Extra Tubing

Recommended Settings
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Materials Thermoformed

 * Kydex
 * Boltaron
 * ABS
 * HIPS
 * PETG
 * Wonderflex
 * Worbla
 * Styrene
 * Cork
 * Leather
 * Plastics
 * Any other types of thermoformed materials

Troubleshooting
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Clean Membrane
The most common reason for the HD vacuum former to lose vacuum is a dirty membrane. Any dust/debris accumulation on the HD vacuum forming membrane may cause the press to slowly lose vacuum. The membrane itself creates the seal with the unique design of the HD Vacuum Press, so it is important to pay close attention to this.

To clean: Run a damp sponge over the entire membrane surface on the side that will contact the work area. Pay particular attention to the region on the membrane that touches the sealing edge on the vacuum former base. You do not need to remove the membrane from the vacuum press to do this. This only takes a few seconds to do.

Edge Allowance's
Before moving on to further troubleshooting steps, double check that your molds are not too close to the outside edge of the heatsink. Modify your molds to provide enough work area around them for the membrane to engage the sealing edge or upgrade to a larger press size if your molds cannot be modified to fit properly.

Use the Heat-sink
The Heatsink Board is an important part of the HD Vacuum Press. To get the best seal possible in your HD Vacuum Press it is vital that you use the heatsink board as a work platform.

Check Internal Plumbing
To check the plumbing underneath the HD Press:

Remove heatsink and switch your vacuum pump on. Open the control valve and plug the vacuum port(s) in the center of the vacuum grid with a wetted thumb. When you have a good seal with your thumb, allow vacuum to build to its highest point, close the control valve, and check the vacuum gauge. Vacuum gauge should not move until you remove your finger. It should hold full vacuum if there are no leaks in the plumbing and fittings attached to the press.

If there are no leaks, your problem is outside the vacuum press system.

Obtain Best Seal
In order for the HD Vacuum Press to hold vacuum pressure without leakage, it must first achieve maximum InHG to seal properly.

First, ensure that you are using a fast enough vacuum pump (3CFM or higher - see below) to fully evacuate all air from the vacuum press.

With the heatsink in place, allow your vacuum pump to fully remove all air from the press and reach approximately 25 InHg or higher on the vacuum press gauge (relative to your elevation above sea level - see below) before closing the vacuum control valve and shutting off your pump. Your vacuum former should now hold vacuum as expected.

Vacuum Forming Policy
The Mechanical Engineering Department maintains the vacuum former for sole use by faculty, staff, and students. The use of the vacuum former shall be consistent with the purpose of the department, which includes facilitating research and learning. In accordance with these purposes, the department has developed policy and procedures for use of the printers:

1.	Administration. All projects (i.e. components) to be formed shall require permission from a faculty member. All projects must originate from U of I classroom, lab, or research. To clarify, personal projects are prohibited.

2.	Certain Uses Prohibited. Regardless of viewpoint, certain uses of the formed are prohibited and violate this Policy:

(a)	Formed any object that is unlawful, threatening, abusive, tortuous, obscene, and racially, ethnically or otherwise objectionable;

(b)	Forming any object that is intended to physically harm, or attempt to harm, an animal or person in any way. This includes any type of weapon (i.e. knives, firearms, etc.) or parts of a weapon (i.e. blades, gun triggers, etc.)

(c)	Forming any object that infringes upon a patent, trademark, trade secret, copyright or other proprietary rights of any party unless consent from the rights-owner has been obtained; The Copyright Law of the United States governs the making of photocopies or other reproductions of copyrighted material. The department reserves the right to deny use of vacuum former's if, in its judgement, use of the former's would violate Copyright Law.

(d)	Vacuum forming any object or any part of an object that is regulated. For example: Undetectable Firearms Act of 1998 which specifically bans plastic firearms.

3.	Usage Subject to Refusal or Revocation. The vacuum former is provided to further the purposes of the department. In accordance with this policy, the department may refuse usage of the vacuum former at any time. Failure to abide by this policy may result in revocation of the user’s forming privileges.