Modern vacuum forming projects almost always begin with a digital design file. The quality and completeness of that file has a direct bearing on the accuracy of the quotation, the timeline for tooling manufacture, and ultimately the quality of the finished part. At Jabro Games, we work with CAD files in a range of formats and want to help clients get the most from the digital design phase of their project.
Preferred File Formats
For three-dimensional parts, STEP (.stp) and IGES (.igs) files are the most universally compatible formats and are preferred by most vacuum forming toolmakers. Parasolid (.x_t) and SolidWorks native (.sldprt) formats are also widely supported. For simpler parts where a fully parameterised 3D model is not available, dimensioned 2D drawings in PDF format are a workable alternative, though they require more interpretation by the toolmaker.
What the CAD Model Should Include
A complete and useful CAD model for vacuum forming should include: accurate overall dimensions, all draft angles applied to vertical walls, specified fillet radii on internal corners, any cut-outs or apertures with their exact dimensions and positions, and notation of any surfaces that have specific finish requirements. If the part will mate with another component, dimensional data for the mating interface is essential.
Design for Manufacture Review
Before tooling commences, our team reviews every design for manufacturability. This review checks that draft angles are present and sufficient, that the draw ratio is within acceptable limits for the chosen material, that internal radii are adequate to prevent tearing during forming, and that there are no features that would prevent the part from releasing from the tool. Issues identified at this stage are far cheaper to address than those discovered after tooling has been made.
Iterating on Digital Files
One of the advantages of modern CAD-based design is the ease with which changes can be made at the digital stage. If our design review identifies modifications, these can typically be made quickly by the designer and a revised file submitted within hours. We encourage clients to treat the design review as a collaborative process — the goal is to arrive at a design that forms reliably and meets all functional requirements.
Submit your CAD files and project brief at jabrogames.com to begin your project.