Here at DaRo we use a wide variety of plastic materials to produce products for a vast range of applications – such a medical equipment, light fittings and product packaging. Many of these products are made using a process known as plastic vacuum forming. But just what does this process entail?

Plastic vacuum forming is one of the most established methods used for processing plastic materials and is employed to make many common items that we regularly use as part of our daily lives.

The process involves making a plastic sheet pliable by heating before placing it over a mould. A vacuum is then used to pull the plastic into the mould. Advanced technology assists the process using computer controlled pneumatic, hydraulic and heat controls to enable faster production speeds and more detailed and consistent vacuum formed shapes.

Range of materials

Depending on the application and structural properties required, here at DaRo we can manufacture in a wide range of materials, including Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Chloride (PVC), Polycarbonate (PC) and High Impact Polystyrene (HIPS). We can also process specialist moulding materials such as chemical resistant, flame retardant, antibacterial and high strength plastics.

Because of the low forming pressures used in the process, tools can be produced at a relatively low cost and moulds can be made in-house from inexpensive materials – all leading to a production cost that is economical.

DaRo’s vacuum forming manufacturing process is high speed and highly accurate. We offer a tailored service, and specialise in batch production, repeat batch work and can also cater for one-offs and prototyping. A diverse range of products are manufactured for a wide range of applications, including machinery covers, point-of-sale displays and enclosures.

We also specialise in the design and manufacture of plastic industrial packaging and transit trays. Many of our customers bring us a sample of the component, and we design and produce a bespoke enclosure or casing to provide protection and support in transit. We also have an in-house design team who offer a complete product design service, as well as providing advice on material selection too.

Environmentally aware

Unlike other thermoplastic forming processes that use powder or resin, vacuum forming uses plastic sheets at as the starting point. In many cases this means a secondary process may be required to trim the formed sheet to give the desired finish. At DaRo all vacuum formed products are finished to the highest standards with computer-controlled routers, drilling and punching equipment used to ensure accurate, high quality and fast drilling, trimming and finishing.

Any waste material from this stage will be granulated and recycled for further use in vacuum forming jobs, resulting in a zero waste manufacturing process that DaRo is proud to offer.