Vacuum Form Mold & Fixtures for Acrylic/ABS Covers

When an American industrial client contracted us to design, cast, and mold a plastic cover for a piece of heavy machinery, Borke Molding Specialists knew we were the right ones for the job. After consulting the customer-supplied STEP file, we knew we could give a quality product back to the client in six weeks turnaround.

We used MasterCam programmed CNC machines to create a foundry pattern to make the permanent alum casting with stainless steel water lines for cooling. We finished the mold with a 200 grit block sanding to make the mold surface as smooth as possible. The Acrylic/ABS material is very shiny and will show any mold defects. We welded a steel draw box and added Lexan windows to aid in the vacuum forming process. A polyurethane board 5-axis trimming fixture is used to hold the plastic part during the 5-axis CNC trimming process. A check gage with tolerance bands CNC cut into the material is use to check the final plastic part for tolerance variation.

The end result was a triumph for Borke. Weighing in at roughly 1,000 lbs., the final plastic component came out to a material thickness of a ¼”, 100″ in length, 26″ in width, and 12″ in height with tightest tolerances of ± 1/32″ and a shrinkage allowance of .006″.

Cast Aluminum Mold

5 Axis CNC Trimming Fixture

Check Fixture

Acrylic/ABS Overlay Materials for a Heavy Machinery Cover Project Highlights

We manufactured this Plastic Cover for use within Heavy Machinery

Aluminum Casting

  • Create Aluminum Casting of Mold

CNC Machining

  • Programming Produced in MasterCAM
  • Machine Foundry Pattern
  • Machine Polyurethane for Check Fixture

Fixture Design & Manufacturing

  • Manufacture Trimming Vacuum Fixture for 5-Axis Machine
  • Manufacture Check Fixture

Welding

  • Weld ¼” Thick Steel Pre-Draw Box

Assembly

  • Assemble Lexan Windows into Pre-Draw Box (So it is Possible to see Part form Over Aluminum mold.)

Final Plastic Component:
Material Thickness: ¼”
Length: 100″
Width: 26″
Height: 12″
Mold:
Length: 103.2″
Width: 30.8″
1 Cavity

± 1/32
Shrinkage Allowance: .006 in/in

Mold:
Cast Aluminum
Steel
Stainless Steel
Copper Tubing
Polyurethane
Plywood
Lexan
Lid:
Acrylic Outside
ABS Inside

  • 200 Grit Block Sanded Smooth

¼” Thick Steel
Ø3/8″ Stainless Steel Tubing
Copper Tubing
Aluminum Plate & Rails
Polyurethane Boards
¾” Plywood
½” Thick Lexan Windows

    • Caliper measurements and paint mold surface then block sand for flatness
  • Heavy Machinery
  • United States

Customer supplied STEP File.

  • Cover Guard