How to Build a Vacuum Former

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Last Updated: March 10, 2025

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• Making the Vacuum Former Box
|
• Making the Platen
|
• Making the Bottom / Mount
|
• Making the Sheet Holder Frame
|
• Using Your New Vacuum Former
|
• Warnings
|
• Things You'll Need

|Show more |Show less

Do you have a need to create molds, masks, or other shapes out of plastic? Make your own 5-inch square vacuum former in just a few hours! The instructions below are based on materials that you might have around the house already or can be modified to use what you do have.

Steps

Part 1

Part 1 of 5:

Making the Vacuum Former Box

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1. 
   1
   Measure and draw your guidelines.

   • On 3/4 inch plywood, draw three squares, 5 inches on a side.
   • Draw another, smaller 4 inch square centered inside each square.
2. 
   2
   Cut along the inner squares on all three frame pieces.
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3. 
   3
   Cut along the outer guidelines to finish each frame piece.
4. 
   4
   Build the main box by stacking and gluing the three frame pieces together.
5. 
   5
   Clamp all four sides of the box and allow the glue to dry.
6. 
   6
   Drill a hole on one side using the hole saw so the vacuum hose (or adapter) will fit snugly.
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Part 2

Part 2 of 5:

Making the Platen

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1. 
   1
   Measure and draw outside frame.

   • On the 5mm MDF, draw a 5 inch square.
2. 
   2
   Measure and draw a grid.

   • Start in from a corner at 0.5 inches from each side, draw straight vertical lines every 2/3 inches for a total of 7 lines.
   • Repeat the pattern for horizontal lines creating an intersecting grid pattern.
3. 
   3
   Drill 3/32 inch holes at each intersection.
4. 
   4
   Cut the final platen out of the MDF along the outside frame lines drawn earlier.
5. 
   5
   Glue the platen to the top of the former box created in the previous step, clamping all four sides until the glue dries.
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Part 3

Part 3 of 5:

Making the Bottom / Mount

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1. 
   1
   Measure and draw cutting guidelines.

   • On the 5mm MDF, draw a 5 inch by 9 inch rectangle.
2. 
   2
   Cut frame from MDF.
3. 
   3
   Glue this final piece to the bottom of the vacuum former box, clamping the two flush sides until the it is fully dried.
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Part 4

Part 4 of 5:

Making the Sheet Holder Frame

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1. 
   1
   Measure and draw guidelines.

   • On the 5mm MDF, draw two 7.5 inch squares
   • Centered inside each square draw another, 5.5 inch square.
2. 
   2
   Cut out the inner square of each frame piece.
3. 
   3
   Cut along the outer guideline to finish the frame pieces.
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Part 5

Part 5 of 5:

Using Your New Vacuum Former

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1. 
   1
   Mount the box.

   • Set the box on a sturdy table.
   • Using the clams / quick clamps, firmly clamp the box to the table.
2. 
   2
   Attach the vacuum.

   • Firmly push the vacuum hose or adapter into the hole on the side of the former.
3. 
   3
   Gather your materials.

   • Cut your desired thermoplastic into 6 inch square sheets.
   • Choose or 3d print shapes to be formed.
4. 
   4
   Place the objects to be molded on the platen (top). Take care to space the part around the holes to maintain clean edges.
5. 
   5
   Clamp the thermoplastic sheet between the frame pieces with the binder clips.
6. 
   6
   Hold frame with grips to keep heat away from your hands.
7. 
   7
   Heat plastic using slow, even motion with the heat gun. Keep going until until the plastic sags about 1.5 to 2 inches
8. 
   8
   Turn on the vacuum.
9. 
   9
   Lower the heated thermoplastic onto former over objects.
10. 
    10
    Continue to heat the thermoplastic around edges and fine details to ensure a clean mold.
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Warnings

• Always adhere proper safety precautions (masks, safety glasses, etc).
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• Use former in a well-ventilated area as some thermoplastics emit toxic fumes when heated.
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Things You'll Need

• 3/4 inch plywood (a little over 75 square inches)
• 5 mm MDF (a little over 127 square inches)
• Wood glue
• Hole saw (sized to fit vacuum hose/adapter) - Typical adapter size is 1-1/2 inch
• 3/32 inch drill bit
• Clamps / Quick Clamps
• Drill
• Jigsaw / Skill saw / Circular saw (whichever is small enough and easy to use)
• Pencil (for drawing guidelines)
• Thermoplastic (Try PETG as it is food safe)
• Heat gun with enough power for your chosen thermoplastic
• Binder clips (x4) to hold sheet inside frame
• Grips to hold frame while heating
• Vacuum cleaner / Shop vacuum with accessory hose