Making a vacuum forming table and casing for console systems!

Thought I would share something I spent time making - a cheap vacuum forming table (cost about £12 to make, about $20) and a mold out of hobbyist air-dry clay.

I have made my first casing half with the mold, using 2mm thick Plasticard (Styrene). I need to fine sand a couple of minor areas before I get my final and perfectly smooth casing.

I wanted to get into vacuum forming to make my cases look nice, better than using perspex (my previous cases)

My vacuum table is crude but works really well.

Details of making it, and lots of pics with step-by-step guide on my website!

Comments welcome!

Pic of the table - as mentioned, it is crude, but works. Very good suction. No point making the table look pretty, it is only to serve a functional purpose after all.



Clay mold, on top of table, ready:



Setup:



Result - need to touch up the clay mold and lightly sand some small areas to get this completely smooth, so my next case top will be perfect. This one was pretty good, three out of four sides perfect (imperfect one showing in pic) and tiny dips in top which need filling and sanding.

 

Your neighbours must be thinking you've got OCD with all the vacuuming going on

That's some neat DIY there, good guide too.
Looking forward to seeing some of the finished cases from it.

 

i will give this a shot in my next vacation.

 

Thanks guys for the comments! Had to make a change to the table:

The vacuum cleaner was destroying the 3mm fibreboard, was literally sucking it out of shape. Replaced with a fresh piece, same thing happened, lost a couple of pieces of plastic due to this.

Replaced the firbreboard with 18mm MDF. There is no way that will bend!

Got a perfect result:











The entire clay mold was completely sucked into the plastic, with a bit of jiggling the clay mold got free easily enough!

Very happy with the result - looks nice, huh?

 

Great job! We used to use a professional vacuum forming machine and it looks as if your home made one does just as good a job as that did. This was back in the early 90's, so I am not sure how far things have progressed. But very nice! :nod:

 

nice setup. I do vacuum forming myself. I bought the company a few years back.

Sorry if I missed it but what are you using to heat the plastic up with? On release agents I know Tap Plastics sells some that would help on the mold release.

 

Taucias - Thanks!

macwest - I just used my home oven, 220 Celcius, fan assisted. You mention about mold release - will it work on clay (porous).

ASSEMbler - Praise indeed! Thanks.

I know the Dyson is very good at suction, from my testing; doesn't have a safety cut-out so just keeps sucking away until I turn it off (after about 10 seconds after plastic has formed). As mentioned before, the suction is powerful enough to destroy 3mm fibreboard in about 10 seconds!! (hence why I went to 18mm MDF). Sides are made airtight with just paper masking tape, does the job!

 

BTW - case coming on nicely. Trimmed off the excess, mapped out exactly where the 5" PSone screen is going.



Progress in my step-by-step guide on BenHeck forum here although when near completion I will detail it more fully on my own website.

 

Now if you could only make a mold of a Sega Neptune.

 

Hey, I have that vacuum!

 

Sorry to ask, but, How does a vacuum forming table works? What kind of plastic do you have to use to make the case? Do you have to heat it before using it in the vacuum forming table? I'm sorry if I made any mistakes when wirting, I'm from Argentina, and english isn't my first language. If i made any mistakes please let me know so I can correct them and learn from them.

 

Principle is that you heat thermo plastic (ABS / Plastic card / Plasticard / Styrene, etc) in an oven so it gets so hot it sags; then put it over a mold, and let air suck the plastic into the grooves around your case so the plastic hugs the mold.

Have a look on my web site for more info, feder, if you are confused.

 

Thanks! Now I understand, but, How much does the plastic cost?

 

About £6 for 8 sheets, cheapest price; including delivery. E-bay.

 

that's really quite nifty!

 

It should. Although if the clay is greasy it achiees the same result. To make quick and inexpensive molds I have used bondo before. It works fine for small runs. Larger runs I use a metalized epoxy

 

As I intend to sell my cases in a few weeks' time, I don't want my mold to break or crack; if I were to varnish it, would that make the surface tougher? Would the heat from the plastic, while cooling, cause issues with varnish?

BTW - case is coming on nicely:



More details on BenHeck forum here

:dance:

 

I have professional level vacuum forming gear if anyone is interested in small levels of replication?? I have produced cart cases in the past amongst other things.

 

How do you attach the front case to the back case?