Blog Post #5 | Jabro Games | jabrogames.com
When planning a plastic component manufacturing project, two processes frequently come under consideration: vacuum forming and injection moulding. Both are well-established and capable techniques, but they have distinct characteristics that make each more suitable for particular applications. Understanding the differences will help you make the right choice for your project.
Tooling Costs
This is perhaps the most significant practical difference between the two processes. Injection moulding requires precision steel tooling that can cost many thousands of pounds to manufacture. Vacuum forming tooling is considerably less expensive, as moulds can be produced from materials such as aluminium, resin, or even wood for prototype applications. For low to medium production volumes, vacuum forming is almost always the more cost-effective choice.
Production Volume
Injection moulding is highly efficient at very high volumes — once tooling costs are absorbed, the per-unit cost becomes very low. Vacuum forming remains competitive across a broader range of volumes, from small prototype runs through to tens of thousands of units, making it the more flexible option for businesses with uncertain or variable demand.
Complexity of Parts
Injection moulding can produce parts with highly complex geometries, undercuts, and internal features that are not achievable with vacuum forming. However, vacuum forming excels in producing large, shallow parts with consistent wall thickness and excellent surface detail — characteristics that suit a wide range of packaging, display, and product applications.
Lead Times
Vacuum forming tooling can typically be produced in days or weeks, compared to several months for injection mould tooling. This makes vacuum forming the preferred option when speed to market is a priority.
The team at Jabro Games will help you assess which process best suits your requirements. Contact us at jabrogames.com to arrange a consultation.