Vacuum Former

Vacuum Forming Machine

Objective

To design and build a custom vacuum forming machine from scratch, overcoming significant constraints in budget, time, and manufacturing resources. The final machine was successfully delivered and is currently in use for producing customized packaging for limited-edition products.

Context

This project was developed for a client with specific production needs, requiring a fully functional vacuum forming machine within a tight deadline. The project was completed in collaboration with a three-person team:

• Myself (Industrial Designer): Led the design, mechanical structure, and fabrication.

• Aerospace Engineer (My Wife): Provided insights on structural and thermal performance.

• Software Engineer: Developed the electronic control system and PCB programming.
  
  

Key Features

• Fully Custom-Built: Designed and fabricated from scratch to meet the client's exact needs.

• Budget-Conscious Engineering: Achieved high functionality while keeping costs low.

• Hands-On Fabrication: Personally executed welding, wiring, and assembly in multiple workshops.

• User-Friendly Design: Optimized for ease of use and integration into the client’s production workflow.

• Successful Industrial Application: Machine is operational in the client’s facility, producing custom packaging.
  
  

Design & Development Process

1. Requirement Analysis & Concept Development

   • Identified client’s production needs and technical constraints.

   • Designed a solution within the given budget and time limitations.
     
     

2. Mechanical & Industrial Design

   • Created the full design considering functionality, material selection, and manufacturability.

   • Ensured optimal ergonomic and structural performance.
     
     

3. Electronics & Software Integration

   • Collaborated with the software engineer to integrate control systems and PCB programming.

   • Designed for efficient temperature and vacuum control.
     
     

4. Prototyping & Fabrication

   • Personally handled welding, wiring, and final assembly in different workshops.

   • Conducted multiple tests to ensure durability and performance.
     
     

5. Final Delivery & Implementation

   • Installed and tested the machine in the client’s company.

   • Machine is now in active use for custom packaging production.