assignments/sample.html Week 16 - Ali Abdul Gafoor - Fab Academy documentation
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Week 16 WILD CARD WEEK

Objectives

Design and produce something with a digital process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it.

Vacuum Forming

Vacuum forming is a manufacturing technique used to shape plastic sheets. In this process, a plastic sheet is heated until it becomes flexible, then a vacuum is applied to pull the sheet tightly over a mold. As the plastic cools, it hardens and takes on the shape of the mold. The formed plastic part is then trimmed to remove excess material and achieve the final product dimensions.

Source: Vacuum Forming Guide

Design Rules

References

Vacuum Forming – A Design Guide (6 Proven Guidelines)

Rule 1: Remove all undercuts

Undercuts make it difficult to remove templates once they have been formed. Make sure your design doesn't have any ledges or indents that could stop a template from being removed.

Photo credit: Mayku Formbox Manual

Rule 2: Add draft angles to vertical faces

Draft angles help in the smooth removal of the formed part from the mold. Ensure that all vertical faces have a slight angle to facilitate easy demolding.

Photo credit: Mayku Formbox Manual

Rule 3: Avoid sharp corners

Sharp corners can lead to uneven material distribution and reduce the overall strength of the formed part. Use radii and chamfers to create smoother transitions.

Photo credit: Mayku Formbox Manual

Final Project Packaging – Aura Smart Hair Oil Dispenser

For the packaging design, 80% of the model was embedded inside the mold while the remaining 20% was allowed to project outward, following standard vacuum forming guidelines.

I began by importing the finalized device model into Fusion 360. The model was then split to isolate the required section for packaging design.

Using a 3D printed mold enabled rapid prototyping and ensured the design was suitable for the vacuum forming process.
  • I created a tangent plane on the side of the dispenser, sketched a rectangle on that plane, and then extruded a 20 mm cut.

    • I projected the surface, extruded it by 10 mm, and applied a 2° taper angle.

    To make it easier to Take the device from the Form, I added a small clearance by creating a spherical feature.

    After finalizing the model and reviewing it with Saheen, I exported the file as an STL and opened it in Bambu Studio. I set the infill to 10% before slicing.

    I enabled tree supports to provide better support during printing.

    I set the wall loops to 3 to increase strength and prevent deformation during vacuum forming.

    I then sliced the model, applied an additional 0.28 draft offset, and sent the file for printing.

    This is the final product after 3D printing.

    Post-Processing

    Using nose pliers, I removed all the tree supports from the model.

    After Post-Processing

    VACUUM FORMING

    For vacuum forming, I used the Mayku FormBox , a compact vacuum forming machine that allows easy and efficient vacuum forming at home or in a workshop.

    Initial Setup

    Setting Temperature and Time

    Each plastic sheet type has a recommended temperature setting (typically levels 1–6) and heating time. These values can be found on the sheet packaging or in the instruction manual.

    For this project, I selected appropriate temperature and time settings based on the material used for forming the packaging component.

    Note: While using a transparent sheet, make sure to peel off the protective layer from the top surface of the clear cast sheet before vacuum forming.

    Locate the timer dial (right dial). Turn it to the recommended heating time. This timer controls how long the sheet will be heated before forming.

    Adjusting Temperature Dial

    Make sure to set the timer dial before adjusting the temperature.

    Heating Status and Material Settings

    • When the FormBox reaches the set temperature, the heater indicator light will turn green. Do not insert the sheet until the light turns green.
    The material used was a 0.5 mm opaque white "Form Sheet", which is easy to use and suitable for applications such as packaging, prototyping, housings, and decorative products.

    The exact material composition was not specified. Based on the manufacturer’s recommendation, the temperature setting was adjusted to level 5 with a heating time between 2:00 to 2:20 minutes.

    Load and Heat Form Sheet

    • Unclamp the tray handles.
    • Remove the protective film from the plastic sheet.
    • Place the sheet onto the bottom tray.
    • Lower the top tray onto the bottom tray and firmly clamp the handles to secure the sheet in position.

    Heating the Sheet

    • Raise the clamped trays upward toward the heater until they click into place.
    • Press the timer start button. The heater indicator light will flash orange, and a slow ticking sound will begin.
    • As the sheet heats, it will become soft and flexible, making it ready for forming.

    Place the mould

    Placing the Mold

    • Place the mold at the center of the vacuum bed.
    • Ensure the mold is not too close to the edges—leave at least 1–2 cm of space around it.
    • Secure the mold if necessary.

    Ready for Forming

    • Once the sheet has softened and become flexible after heating, pull the tray down over the mold. The vacuum will activate automatically, forming the sheet around the mold.
    Working Demo

    Cooling and Removal

    • After vacuum forming, leave the sheet in place for 1–2 minutes to cool and harden.
    • Once cooled, unclamp the tray handles and carefully open the frame to release the formed sheet. Gently lift the formed plastic off the mold.

    Hero shot

    Issues Faced and Improvements

    During the vacuum forming process, deformation occurred in the mold after repeated heating cycles.

    After 2–3 forming attempts, the top surface of the mold began to deform due to heat exposure. This affected the final output quality, especially in the highlighted region where surface accuracy is critical.

    Reason for Issue

    • The mold material was not sufficiently heat-resistant.
    • Repeated exposure to high temperature caused softening and deformation.
    • Thin sections of the mold were more prone to distortion.

    Improvements

    • Use heat-resistant materials such as PETG or ABS.
    • For better durability, mill the mold using ShopBot plywood.
    • Increase mold thickness to improve strength.
    • Add proper draft angles to reduce stress during forming.
    • Optimize heating time to avoid overheating.
    • Allow cooling time between cycles to prevent heat buildup.
    Conclusion

    Conclusion

    • The vacuum forming process is an effective and versatile method for creating molds and packaging components. It requires careful design considerations to ensure proper material flow, easy demolding, and accurate final results.
    • By following the design rules and optimizing process parameters, high-quality formed parts can be achieved. Addressing issues such as mold deformation through proper material selection and design improvements is essential for successful vacuum forming.

    References

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