The terms vacuum forming and thermoforming are frequently used interchangeably, and while there is significant overlap between them, they are not identical. Understanding the distinction helps clients communicate their requirements more precisely and ensures the right process is selected for each application. At Jabro Games, we are happy to guide clients through the options.
What Is Thermoforming?
Thermoforming is the broader category — it refers to any process that involves heating a thermoplastic sheet and forming it over a mould. Vacuum forming, pressure forming, and twin-sheet forming are all variants of thermoforming. When people refer to thermoforming generically, they usually mean the broader family of processes rather than a specific technique.
Vacuum Forming Specifically
Vacuum forming uses atmospheric pressure — created by drawing a vacuum beneath the heated sheet — to pull the plastic onto the surface of the mould. It is the simplest and most widely used form of thermoforming, capable of producing a wide range of parts cost-effectively. It works best for parts with relatively simple geometry and moderate detail requirements.
Pressure Forming: Higher Detail
Pressure forming adds positive air pressure above the heated sheet in addition to the vacuum below, forcing the plastic more firmly against the mould surface. This produces sharper detail, crisper edges, and better replication of textured mould surfaces. The result is a part that more closely resembles injection moulding in quality, at a fraction of the tooling cost.
Which Process Is Right for Your Application?
For most applications — packaging inserts, trays, display components — standard vacuum forming delivers excellent results at the lowest cost. Where sharper detail, textured surfaces, or tighter tolerances are required, pressure forming should be considered. Our team at Jabro Games will assess your requirements and recommend the most appropriate process. Get in touch at jabrogames.com.