[Thermoforming Applications] Vacuum Forming VS Pressure Forming: What's the Difference? We'll Tell You All About It!

Vacuum forming and pressure forming are both thermoforming technologies. However, they differ significantly in terms of "finished product appearance," "technical principles," "common materials," and "application scope." The video by the founder of Mayku compares these differences side-by-side, and this article also provides a comparative chart of practical applications for a more comprehensive evaluation!

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【Finished Product Effect】

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First, the plastic sheet is inserted into the compression molding machine, positioned above the mold. Heating is then applied from above. Once the appropriate temperature is reached, pressurized air pushes the plastic sheet onto the mold. Ventilation vents expel any incoming air. Once fully cooled and hardened, the plastic sheet is removed from the mold, producing a plastic shell that can be modified and adjusted to specific specifications.

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thermoformed plastic sheets
Vacuum forming and pressure forming are both suitable for the same plastic sheets, although pressure forming can typically use thicker plastic sheets than vacuum forming and can be used for thicker parts.
High-impact polystyrene ( HIPS ): stable, low-cost, and impact-resistant .
EVA : It has low-temperature toughness and UV resistance .
PETG : Good hardness, chemical resistance, impact resistance, transparency and ductility, suitable for food-grade tools or parts.
Low -density polyethylene (LDPE): It can withstand high temperatures, is resistant to chemical corrosion, and is soft and elastic .
Other materials used in pressure forming and vacuum forming include:
Acrylic (PMMA)
Acrylonitrile butadiene styrene (ABS)
Polycarbonate (PC)
Polyethylene (PE)
Polypropylene ( PP )
Polystyrene (PS)
Polyvinyl chloride (PVC)
Other plastic sheets, etc.


Thermoforming template
In vacuum forming, male templates are the most common . The materials used are usually thinner, and the level of detail expected in applications such as packaging is not high.
In pressure forming, the master mold is the most common type of mold used . It is typically used to create molds or parts with high-level details, textures, or other aesthetic appeal.

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Comparison of the advantages of the two technologies