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Going Bespoke: Building a Custom Vacuum Forming Machine for the Medical Technology Sector

Going Bespoke: Building a Custom Vacuum Forming Machine for the Medical Technology Sector

Ensuring compliance with clean room and corrosion resistance standards

Ensuring compliance with clean room and corrosion resistance standards

July 10, 2024

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Formech is frequently approached to build bespoke vacuum forming machines for customers.

Whether this involves modifications to standard vacuum forming machines or ground-up custom builds for more challenging applications, the approach is always the same.

In each case we conduct a very thorough needs analysis to determine the exact requirements of our customers. This includes research on materials, tooling, production calculations, simulations, and testing, as well as machine location and operating environment, and statutory or regulatory requirements.

Many of these customers are either bringing the vacuum forming process in-house for the first time or rely on less experienced machine operators, so we offer support throughout the process to ensure they fully understand the proposals and suggestions we make.

Medical-grade solution

One Formech customer is a leading developer and manufacturer of proprietary materials in the medical technology sector.

It requested a custom-made vacuum forming machine based on our HD686 semi-automatic model, with adjustments made to ensure ease of use for operation in a clean room environment, as well as a high corrosion resistance.

Formech HD686
Standard Formech HD686

The Formech team designed a machine built using high quality type 304 / 316 grade stainless steel to ensure the superior hygiene and resistance standards required.

Medical grade HD686
Medical grade HD686

The upper section of the machine and forming area were mainly constructed using a strong, durable, and corrosion resistant alloy instead of the standard powder coated steel. At the same time, all the pneumatic control valves and cylinders were changed to stainless steel housings, as well as the enclosure for the 10" hi-res touchscreen that houses the PLC control.

Medical grade HD686 Forming area
Medical grade HD686 Forming area
10
10" hi-res touchscreen PLC control

Optimal Heating Control

One of the key requirements of the machine was the need to control the heat output. Working with the customer, a modified heater layout was agreed. In turn, each individual element was fitted with a thermocouple for full feedback control to allow a target temperature to be set and accurately maintained. For monitoring purposes, multiple pyrometers were strategically located around the forming area to observe the heating and cooling phases.

Stainless steel components
Stainless steel components

Customised Processing Equipment

As part of the vacuum forming and manufacturing process, the customer wanted to ensure the formed plastic was processed and finished with machinery of the same medical-grade specifications. We modified a RP700 roller press, which uses a cutting die to cleanly separate waste material from the finished part, to clean room standards and replaced several components with a stainless steel alternative.

RP700 roller press
RP700 roller press

Hitting the Brief – and Ordering More

Following the installation, the customer's team monitored the operation of its customised HD686, and our team worked closely with them to ensure all parts of the specifications were being delivered. The customer was so pleased it ordered a second machine.

Stainless stell controls
Stainless stell controls

Creating Your Bespoke Machine

To find out how we can help design your custom vacuum forming machine, complete our Find Your Solution form with as much information as you have. This will allow us to begin researching your project and set-up a meeting to discuss it further. You can also contact us for any enquiries.

Medical grade HD686 stainless steel body and pump
Medical grade HD686 stainless steel body and pump
Medical grade HD686 electronics and controls
Medical grade HD686 electronics and controls

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