There are several ways to trim your vacuum formed molds. Some of these methods are more suited for lab or classroom environments, while others are what you’d find at large production facilities.
Trimming by hand
Trimming by hand is the most common method used in classrooms where students are learning vacuum forming technology with one-off projects (as opposed to a manufacturing company operating large production runs). Softer, less brittle materials can be scored with a sharp blade (roughly half the thickness of the material) and then snapped away from you for a clean break.
Trimming with a vertical band saw
When the trimmed edge of your part is not critical, a band saw can be used for rough cutting. This method won’t always give you a consistent cut and it will leave a slightly jagged edge that may need scraping for a cleaner finish.
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Trimming with a drill press and slitting saw
In this instance, the vacuum forming is usually rough cut to remove the excess material before it is pushed into the rotating slitting saw and slit all around the circumference to remove the waste from the part. The clean edges may only need slight scraping.
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Trimming with an overhead or table mounted router with guide pin/bearing cutter/slitting saw
This method is favored when you need a clean cut, consistent edge. The vacuum forming is rough cut on a band saw before pushed into the rotating slitting saw and slit all around the circumference. A mounted guide pin guides the cutter for a clean, accurate edge.
Trimming with a roller press
Roller presses are recommended for materials that are less than 1mm thick. This method is common for manufacturers producing large quantities of thin package trays and inserts.
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Trimming with a horizontal band saw
Also for large production quantities, this method is favored for materials ranging from 0.5mm – 3.0mm in thickness. It can require scrapping along the edge of your part.
Trimming with a 3 or 5 axis router
This method leaves a very clean accurate edge that often does not require additional cleaning. It is recommended for production quantities that require clean, consistent cuts.
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Trimming with a robot
The most complex production level trimming method, this will give you clean, consistent, accurate parts. It is often used when manufacturers need to save time and reduce production costs.
For more on popular vacuum forming trimming methods, head over to Formech’s website.
