UNSW Making

Thermoforming Plastics

Tutorials, guides, material advice and more! All the things you need to know about thermoforming plastics in the workshop
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What is plastic?

Precious plastic describe this well,

The word itself is derived from the Greek plastikos meaning “capable of being shaped or moulded” and refers to their malleability during manufacture that allows plastic to be cast, pressed or extruded into a variety of shapes—like films, fibres, plates, tubes, bottles and much more.

Plastics are synthetic chemicals extracted mainly from petroleum and made of hydrocarbons (chains of hydrogen and carbon atoms). Most plastics are polymers, long molecules made up of many repetitions of a basic molecule called a monomer and this structure makes plastic particularly durable and long lasting. Due to their relatively low cost, ease of manufacture and versatility, plastics are used in an enormous and expanding range of products, from shampoo bottles to space rockets.

Different Plastic Types

Types of plastics

Thermoset

Thermoset plastics contain polymers that cross-link together and create an irreversible bond, meaning they can’t be remelted - once they take shape, they will be solidified forever. Resin is a really good example of a thermoset plastic. None of these plastics can be recycled.

Thermoplastic

Thermoplastics is a plastic polymer which becomes soft when heated and hard when cooled. Thermoplastic materials can be cooled and heated several times: when they are heated, they melt to a liquid and when they cool they become hard.

Thankfully, 80% of plastics in the world are thermoplastics meaning they can be recycled and transformed. Thermoplastics are divided into further subcategories depending on their structure and properties, and can be recognised by their name or number as seen below.

Elastomers

Elastomers are somewhere between thermoset and thermoplastic and examples of these are natural rubber, silicone or for example neoprene (yes, that stuff were wetsuits are made from)


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Plastics in the Design Futures Lab

Plastic Pile

Where possible in the Design Futures Lab we use plastics that are recyclable. We endeavour to recycle our plastic waste responsibly and try to do as much of it ourselves as possible!

We ask that users of the workshop think about the all the materials they use and their impact.

In the polymers lab we use the following materials:

HDPE - High Density Polyethylene - Recycling symbol 2

PETG - Polyethylene Terephthalate Glycol

HIPS - High Impact Polystyrene

PLA - Polylactic Acid

Acrylic - PMMA - Poly(methyl methacrylate)

HIPS - High Impact Polystyrene

Vacuum Forming

What is Vacuum Forming?

Vacuum forming is a manufacturing method used to shape plastic materials. During the vacuum forming process, a sheet of plastic is heated and then pulled around a single mold using suction.

Vacuum forming is used for a wide range of manufacturing applications, ranging from small custom parts produced on desktop devices to large parts manufactured on automated industrial machinery.

Vacuum Forming at the DFL


Graphic with Frame Sizes


Possible Mould Materials

Metal

Timber

Ceramic

3D Printed

VacForm2
VacForm1

Possible Plastics:

Polystyrene (PS)

P (PETG)

Acrylic (PMMA)

Injection Moulding

Coming soon

Sheet Press

Coming soon

Shredder

Coming soon

Extruder

Coming soon

Get Inspired

Moulding HDPE

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