Three Production Processes of Vacuum Forming Dashboards
1. ABS composite sheet vacuum forming
Material selection: We usually use two types of ABS composite sheet for vacuum forming. PVC/ABS laminate sheet combine the chemical resistance of PVC and the impact strength of ABS, while TPU/ABS composite sheet have enhanced durability and elasticity due to the unique properties of TPU. The thickness of these sheet is usually between 2-5 mm, depending on the requirements of the dashboard design.
Post-processing: The surface of the ABS composite sheet has a soft cortical layer. After vacuum forming, the edges can be cut and used directly without any additional tedious processes. After forming, take out the molded piece and use precision cutting tools(CNC machine) to trim off the rough edges or excess material.
2. PVC/ABS alloy film vacuum forming and foaming
Semi-rigid sheet vacuum forming: PVC/ABS film is usually 60-80% PVC and the rest is ABS. Put it into the vacuum forming machine, and the machine heats the PVC/ABS alloy sheet to a temperature range of 100-130°C for vacuum forming.
Reinforcement and foaming: After the PVC/ABS alloy sheet is vacuum formed, the next key step is reinforcement and foaming. Glass fibers in short filament or mat form provide enhanced mechanical strength for dashboard molding. Foaming material is injected to form a lightweight but strong structure, and the panel is then placed in an oven or specialized foaming chamber, which activates the foaming agent, causing it to break down and release bubbles. These bubbles expand within the panel, forming a network of voids that not only reduces the weight of the panel but also increases its rigidity.
3. Dashboard Injection Molding
Injection Mold Development: Dashboard injection molding begins with the design and manufacture of highly complex injection molds. . High-quality steel is used for mold manufacturing, which requires a significant investment in terms of time and cost.
Injection Molding Process: Dashboard injection molding is a technically demanding process. The large size and complex shape of the dashboard require precise control of parameters such as temperature, pressure, and injection speed. Any deviation in these parameters can lead to defects such as warping, sink marks, or incomplete cavity filling. In addition, the initial investment in injection mold development is huge, and any design changes during the development phase can be costly and time-consuming.
Why Choose Vacuum Forming for Dashboard Manufacturing?
Vacuum Forming, as the core process of thermoplastic sheet processing, is becoming the preferred solution for automotive dashboard manufacturing. It softens the plastic sheet by heating and uses vacuum adsorption to form it, which can achieve complex curved surface design while reducing production costs by 30%-50%
Core Advantage Comparison:
✅ Design freedom: clear texture details, choose the right ABS sheet for vacuum forming
✅ Cost saving: much lower than the cost of injection molding process
✅ Lightweight breakthrough: ABS molded parts are more than 40% lighter than metal parts
✅ Fast delivery: only 3-4 weeks from mold development to mass production
How to choose a high-quality vacuum forming supplier?
Equipment precision: servo-driven vacuum forming machine Material
library depth: at least 20+ certified plastic sheets Sustainable
production: ISO 14001 environmental management system certification
JIANGSU COMPOUND has been specializing in Automotive ABS Plastic Sheet for 18 years, has its own extrusion equipment and vacuum forming equipment, and focuses on the performance research and development of various sheets and the design and manufacture of bus dashboards. Contact us: whatsapp: +8613773555916
e-mail: info@absgoods.com
