Can The Plastic Used In Vacuum Forming Be Repaired?

December 4, 2023 3:02 pm Published by Leave your thoughts

Vacuum,Forming,Machine,For,Making,Plastic,Pack,Or,MoldingWhen it comes to vacuum forming, the plastic materials used can sometimes get damaged or develop defects during the forming process. This raises the question: can the plastic used in vacuum forming be repaired? In this blog post, we will explore this topic in detail.

Understanding Vacuum Forming

Vacuum forming is a manufacturing process that involves heating a plastic sheet until it becomes pliable, then stretching it over a mold and using a vacuum to remove the air between the sheet and the mold. The plastic then cools, solidifies, and takes the shape of the mold.

Types of Plastic Used in Vacuum Forming

There are several types of plastic that can be used in vacuum forming, including acrylic, ABS, polystyrene, and PVC. The type of plastic chosen depends on the specific requirements of the project, such as the desired strength, durability, transparency, or flexibility of the final product. These plastic sheets are commonly available in various thicknesses, allowing for a range of applications.

Damage and Defects in Vacuum Formed Plastics

During the vacuum forming process, the plastic sheet can sometimes be subjected to stress, leading to damage or defects. Common issues include warping, cracking, tearing, or air bubbles forming within the plastic. Additionally, improper cooling or handling of the formed plastic can also result in problems such as warping or deformation.

Can Vacuum Formed Plastic Be Repaired?

While it is possible to repair certain defects in vacuum-formed plastics, the level of repair will depend on the severity and nature of the damage. Let’s discuss some commonly observed issues and potential repair methods:

1. Warping: Warping is a common problem in vacuum-formed plastics. In some cases, gentle heat application and careful manipulation of the plastic can help reduce or eliminate the warp. However, severe warping may require more drastic measures, such as re-heating the plastic and reforming it on a new mold.

2. Cracking and Tearing: Small cracks or tears in the plastic can often be repaired by applying a compatible adhesive that bonds the broken pieces back together. This method works best for minor damage. However, extensive or deep cracks may require more complex repairs, such as using reinforcing materials or hot air welding techniques.

3. Air Bubbles: Air bubbles trapped within the plastic can be challenging to repair. One possible solution is to drill small holes near the bubbles and fill them with a compatible liquid or adhesive. This method helps release the trapped air and can effectively resolve the issue in some cases.

4. Deformation: Plastic deformation caused by improper cooling or handling can sometimes be repaired by applying heat to the affected area and gently reshaping the plastic back into its original form. Proper cooling and handling techniques during the forming process can help prevent this issue altogether.

Consulting Professionals for Repairs

While it is possible to carry out some repairs on vacuum-formed plastics, it is essential to consider consulting with professionals who specialize in plastic repairs. These experts have the knowledge and experience to assess the damage accurately and determine the most suitable repair method. Additionally, they can provide guidance on preventative measures to avoid future damage.


The plastic used in vacuum forming can be repaired to some extent, depending on the nature and severity of the damage. Small issues like warping, cracks, tears, and air bubbles can often be resolved through various repair techniques. However, significant damage may require more complex repairs or even the complete reformation of the plastic. Consulting professionals in plastic repairs is highly recommended to ensure the best outcomes.

Need a Plastic Fabrication Company in Orem, UT?

D&D Plastics is a design and development company that assists clients in taking a concept or design and developing it into a viable product. With over 35 years of experience in vacuum forming and fabrication, we are pushing the boundaries of what we can do with plastic today. At D&D Plastics, if you can think it up, we can make it! We specialize in custom plastics, sheets of plastic, tubing, thermoforming, vacuum forming, acrylic, plastic rod, ABS and polycarbonate, and MUCH more. We love what we do and strive to become the best. We focus on creating a win-win with our customers and want them to succeed and grow with us. Our customers always have, and always will come first, and no project is too small! Contact us today and learn more about what we can do for you!

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