1.Master model creation: The process begins with the creation of a master model, typically using techniques like 3D printing, CNC machining, or hand sculpting. The master model should be precise and detailed because it will be used to create the silicone mold.
2.Silicone mold making: A silicone mold is then created from the master model. This is done by pouring liquid silicone rubber around the master model and allowing it to cure. The result is a flexible silicone mold that accurately replicates the details of the master model.
3.Vacuum forming: Once the silicone mold is ready, it is placed in a vacuum forming machine. A sheet of thermoplastic material, such as ABS or polycarbonate, is heated until it becomes pliable. The heated sheet is then draped over the silicone mold, and a vacuum is applied underneath. The vacuum sucks the heated plastic tightly against the mold, forming a precise replica of the master model.
4.Cooling and solidification: After forming, the plastic is allowed to cool and solidify while still in contact with the silicone mold. This ensures that the replica retains the details and dimensions of the master model.
5.Demolding: Once the plastic has cooled and hardened, the silicone mold is removed, leaving behind the formed plastic part. The part may require additional finishing, such as trimming excess material or surface smoothing, depending on the desired final appearance.
6.Repeat process: The vacuum forming process can be repeated multiple times using the same silicone mold to produce multiple replicas of the master model. This makes it suitable for small-scale production runs or rapid prototyping.
