One of the most important decisions in any vacuum forming project is selecting the correct sheet thickness. Get it right and the finished part will have the strength, rigidity, and appearance the application demands. Get it wrong and even the best tool and forming process will produce a part that disappoints. At Jabro Games, we guide every client through this decision as part of our standard project process.
Understanding Draw Ratio and Wall Thickness
When a plastic sheet is formed over a mould, it stretches — and as it stretches, it thins. The amount of thinning depends on the draw ratio: the relationship between the depth of the form and its width. A deep draw over a small area can result in significant thinning at the base and corners of the part. Selecting a thicker starting sheet compensates for this thinning and ensures adequate wall thickness in the finished component.
Thin Gauge: Up to 1.5mm
Thin gauge sheet is used for applications where flexibility, low weight, and cost efficiency are priorities — blister packaging, food trays, medical packaging, and disposable products. Parts formed from thin gauge sheet are typically trimmed and used in single use or short-life applications.
Medium Gauge: 1.5mm to 3mm
Medium gauge is the most versatile range and covers the majority of packaging, insert tray, and display component applications. It provides a good balance of rigidity and formability, and is suitable for parts that need to retain their shape under moderate load or repeated handling.
Heavy Gauge: 3mm and Above
Heavy gauge forming is used for structural components, industrial trays, vehicle interior panels, and any application where high rigidity and impact resistance are essential. Parts formed from heavy gauge sheet are typically used in permanent or long-service applications where durability is paramount.
Our team at Jabro Games will advise on the optimal sheet thickness for your specific application. Contact us at jabrogames.com.