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Do you have a need to create molds, masks, or other shapes out of plastic? Make your own 5-inch square vacuum former in just a few hours! The instructions below are based on materials that you might have around the house already or can be modified to use what you do have.
Steps
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![Step 1 Measure and draw your guidelines.]()
Measure and draw your guidelines.- On 3/4 inch plywood, draw three squares, 5 inches on a side.
- Draw another, smaller 4 inch square centered inside each square.
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![Step 2 Cut along the inner squares on all three frame pieces.]()
Cut along the inner squares on all three frame pieces.Advertisement -
![Step 3 Cut along the outer guidelines to finish each frame piece.]()
Cut along the outer guidelines to finish each frame piece. -
![Step 4 Build the main box by stacking and gluing the three frame pieces together.]()
Build the main box by stacking and gluing the three frame pieces together. -
![Step 5 Clamp all four sides of the box and allow the glue to dry.]()
Clamp all four sides of the box and allow the glue to dry. -
![Step 6 Drill a hole on one side using the hole saw so the vacuum hose (or adapter) will fit snugly.]()
Drill a hole on one side using the hole saw so the vacuum hose (or adapter) will fit snugly.
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![Step 1 Measure and draw outside frame.]()
Measure and draw outside frame.- On the 5mm MDF, draw a 5 inch square.
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![Step 2 Measure and draw a grid.]()
Measure and draw a grid.- Start in from a corner at 0.5 inches from each side, draw straight vertical lines every 2/3 inches for a total of 7 lines.
- Repeat the pattern for horizontal lines creating an intersecting grid pattern.
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![Step 3 Drill 3/32 inch holes at each intersection.]()
Drill 3/32 inch holes at each intersection. -
![Step 4 Cut the final platen out of the MDF along the outside frame lines drawn earlier.]()
Cut the final platen out of the MDF along the outside frame lines drawn earlier. -
![Step 5 Glue the platen to the top of the former box created in the previous step, clamping all four sides until the glue dries.]()
Glue the platen to the top of the former box created in the previous step, clamping all four sides until the glue dries.
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![Step 1 Mount the box.]()
Mount the box.- Set the box on a sturdy table.
- Using the clams / quick clamps, firmly clamp the box to the table.
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![Step 2 Attach the vacuum.]()
Attach the vacuum.- Firmly push the vacuum hose or adapter into the hole on the side of the former.
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![Step 3 Gather your materials.]()
Gather your materials.- Cut your desired thermoplastic into 6 inch square sheets.
- Choose or 3d print shapes to be formed.
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![Step 4 Place the objects to be molded on the platen (top).]()
Place the objects to be molded on the platen (top). Take care to space the part around the holes to maintain clean edges. -
![Step 5 Clamp the thermoplastic sheet between the frame pieces with the binder clips.]()
Clamp the thermoplastic sheet between the frame pieces with the binder clips. -
![Step 6 Hold frame with grips to keep heat away from your hands.]()
Hold frame with grips to keep heat away from your hands. -
![Step 7 Heat plastic using slow, even motion with the heat gun.]()
Heat plastic using slow, even motion with the heat gun. Keep going until until the plastic sags about 1.5 to 2 inches -
![Step 8 Turn on the vacuum.]()
Turn on the vacuum. -
![Step 9 Lower the heated thermoplastic onto former over objects.]()
Lower the heated thermoplastic onto former over objects. -
![Step 10 Continue to heat the thermoplastic around edges and fine details to ensure a clean mold.]()
Continue to heat the thermoplastic around edges and fine details to ensure a clean mold.
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Warnings
- Always adhere proper safety precautions (masks, safety glasses, etc).Thanks
- Use former in a well-ventilated area as some thermoplastics emit toxic fumes when heated.Thanks
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Things You'll Need
- 3/4 inch plywood (a little over 75 square inches)
- 5 mm MDF (a little over 127 square inches)
- Wood glue
- Hole saw (sized to fit vacuum hose/adapter) - Typical adapter size is 1-1/2 inch
- 3/32 inch drill bit
- Clamps / Quick Clamps
- Drill
- Jigsaw / Skill saw / Circular saw (whichever is small enough and easy to use)
- Pencil (for drawing guidelines)
- Thermoplastic (Try PETG as it is food safe)
- Heat gun with enough power for your chosen thermoplastic
- Binder clips (x4) to hold sheet inside frame
- Grips to hold frame while heating
- Vacuum cleaner / Shop vacuum with accessory hose
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