SME Plastic is a professional custom aluminum vacuum forming molds manufacturer from China, our pure aluminum thermoforming molds, made from #6061 or #7075 aluminum, offer excellent heat conductivity and high precision. They are ideal for standard vacuum forming machines and three-station or four-station forming lines. These molds ensure consistent results in medium to high-volume production.
Aluminum Vacuum Forming Mold Products
Pure Aluminum Vacuum Forming Mold Production Process
Requirement Analysis & Design
Product Input
We begin by receiving a 3D model or physical sample from the customer. The product’s dimensions, shape, accuracy requirements (±0.1–0.5mm), and production volume (aluminum molds are typically suitable for runs under 100,000 cycles) are clearly defined.
Mold Design
Using CAD software (such as SolidWorks, Pro/E, UG, or AutoCAD), we complete the mold-splitting design and determine the draft angle (usually 1°–3°) and parting lines.
The layout of vacuum holes is optimized (hole diameter: 0.8–1.5mm; spacing: 10–30mm) to ensure even suction and consistent forming.
Optional Cooling System
For higher production needs, embedded copper pipes or internal flow channels are designed to improve heat dissipation.
Material Selection
Aluminum Type
We mainly use 6061-T6 (moderate strength, easy to machine) or 7075 (high strength, wear-resistant). The aluminum block should have a machining allowance of 5–10mm.
Additional Components
Vacuum connectors, sealing strips, and mounting bases (usually made of steel frames) are also prepared.
CNC Machining
Rough Machining
Using 3-axis or 5-axis CNC milling machines, large amounts of material are removed. The rough milling tolerance is controlled within ±0.2mm.
Finish Machining
Ball-end or fine engraving tools are used to complete the cavity surface machining, achieving a surface roughness of Ra ≤ 3.2μm.
Vacuum holes are drilled using a peck drilling process to prevent aluminum chip clogging.
A 0.05mm allowance is reserved on critical fitting surfaces for polishing.
Surface Treatment
Sandblasting
Aluminum oxide sand (120–220 mesh) is used to improve surface adhesion and prepare for further treatment.
Anodizing
Hard anodizing (30–50μm thick) increases surface hardness (up to HV400) and corrosion resistance.
Optional Teflon Coating
For materials with high stickiness (e.g., PVC), a 5–10μm Teflon layer can be applied to improve mold release.
Vacuum System Integration
Hole Optimization
Main vacuum channels are drilled with diameters of 8–12mm. Branch holes decrease in size, and filters are added at the ends to prevent clogging.
Sealing Test
Compressed air (0.3–0.5MPa) is used to check for leaks. A maximum pressure drop of ≤5% per minute is acceptable.
Assembly & Testing
Mold Installation
The aluminum mold is securely mounted on a steel base plate. The flatness error is controlled within ≤0.1mm/m.
Trial Run:
Heating Temperature
Adjusted based on material type (e.g., APET: 120–140°C, PVC: 130–160°C).
Vacuum Pressure
Controlled at -0.08 to -0.095MPa, with a holding time of 2–5 seconds.
Parameter Optimization: Heating and cooling times are fine-tuned. Aluminum molds typically cool 30% faster than steel molds.
Quality Inspection
Dimensional Accuracy
A Coordinate Measuring Machine (CMM) checks key dimensions with a tolerance of ±0.1mm.
Forming Test
20–50 trial parts are continuously formed to inspect thickness uniformity (±10%) and edge definition.
Vacuum Pressure
Controlled at -0.08 to -0.095MPa, with a holding time of 2–5 seconds.
Parameter Optimization: Heating and cooling times are fine-tuned. Aluminum molds typically cool 30% faster than steel molds.
Custom Quote
Looking for precise and durable aluminum vacuum forming molds? Contact us today through below form to get a free custom quote tailored to your project needs.
CONTACT US
- Guangzhou SME Plastic Corp
- E-mail: [email protected]
- Mob: +86-13928889690
- Whatsapp: +86-13928889690
- Address: No.10, 3rd st, Minying Industrial Zone, Shawan Town,Panyu District, Guangzhou City, Guangdong, PRC
