INSIGHTS
OCTOBER 18, 2025 • 6 MIN READ
5 unique advantages of using vacuum forming
Vacuum forming has a wide range of applications, but what are the biggest advantages of this production method?
Geir Bergh
Head of Office, Plexx
Advantages of vacuum forming include relatively low production costs, the ability to create complex shapes and details, and the flexibility to work with different types of thermoplastic materials. This process is used across a range of industries – for example fisheries and aquaculture, the automotive, bus and truck industries, medical equipment and much more. Here are some of the unique advantages of vacuum forming.
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Cost-effectiveness
Vacuum forming is generally an affordable production method. Tooling costs are relatively low compared to methods such as injection molding, and the process is fairly easy to automate – which can significantly reduce the price of the finished product.
2. Rapid prototyping
Vacuum forming allows for rapid production of prototypes and small series, making it ideal for testing and modifying designs before full-scale production begins – you can validate geometry, assembly and function without major investments in tooling.
3. Flexibility in material choice
Vacuum forming can be used with a variety of thermoplastic materials – such as ABS, PETG, HIPS, PC and PMMA. This gives customers the flexibility to choose the material that best suits their specific product, based on strength, optics, chemical resistance and temperature requirements.
4. Ability to create complex shapes
Vacuum forming allows the production of products with complex shapes, details and textures, making the method particularly suitable for products with special design requirements – from ribs and reinforcements to sharp radii and integrated functional elements.
5. Material waste is recycled
All material waste generated during vacuum forming is 100% recycled. This means the method is also an environmentally friendly option – surplus material from trimming and edging goes straight back into the cycle and is used for new production.
"We go beyond just delivering finished products – we work closely with our customers and provide advice so that together we find the optimal solution."
Extensive experience and a broad customer base in Europe
Plexx has extensive experience in vacuum forming and works with a broad customer base throughout Europe. All of our subsidiaries and affiliates are quality and environmental certified according to ISO 9001 and 14001.
Questions and answers
The tooling costs for vacuum forming are relatively low compared to methods such as injection molding, and the process is relatively easy to automate. This reduces the price of the final product and makes the method particularly attractive for small and medium-sized series.
Yes, vacuum forming is an ideal method for rapid prototyping and small series production. You can test geometry, assembly, and function — and make design changes — before full-scale production begins.
Vacuum forming can be used with a variety of thermoplastic materials such as ABS, PETG, HIPS, PC and PMMA, giving customers the flexibility to choose the material that best suits their specific product based on strength, optics, chemical resistance and temperature requirements.
Vacuum forming allows the production of products with complex shapes, details and textures — including ribs, reinforcements, sharp radii and integrated functional elements. The method is therefore well suited for products with special design requirements.
All waste material that occurs during vacuum forming is 100% recycled. Excess material from trimming and edging goes straight back into the cycle and is used for new production — making vacuum forming an environmentally friendly option.
Vacuum forming is used in a variety of industries, including fisheries and aquaculture, the automotive, bus and truck industries, medical devices, transportation, packaging and industrial covers.
All of our subsidiaries and affiliates are quality and environmental certified according to ISO 9001 and 14001. We have extensive experience in vacuum forming and work with a broad customer base throughout Europe.