Pressure Forming Molds

Pressure Forming Molds Overview

Pressure Forming Molds are similar to Vacuum Forming Molds are similar in characteristics in that they both utilize vacuum to assist in creating desired product designs/molds. Understanding the slightest details that make each of the Pressure Forming Molds different is vital to providing all of our customers with Thick-gauge molds of the highest quality.

Our skilled Borke MS technicians have many years of experience of working with many different types of materials to develop Pressure Forming Molds for our clients. Some of those materials are, CNC machine aluminum, cast aluminum, wood, epoxy boards and polyurethane boards.

We work with CAD/CAM software programs so that all of your molds are produced to your required standards and tolerances of +/- 0.005. Typical project turnaround is 2 – 8 weeks depending on the type of mold and its application. With Borke Mold Specialists you know that your Pressure Forming Molds will be done right the first time.




Pressure Forming Mold Specifications

  • Vacuum forming molds thin gage
  • Vacuum forming molds thick gage
  • Thermoforming molds thin and thick gage
  • Cut-In-place forming molds
  • Twinsheet molds
  • Cast aluminum
  • CNC machine aluminum
  • Wood
  • Polyurethane boards
  • Epoxy board
  • Vertical milling
  • Deep hole gun drilling
  • MIG and TIG welding in aluminum or steel
  • Sawing / Cutting
  • Drilling vacuum holes from #80 – 3/64″
  • Sand blasting and polishing mold surface
  • Soldering water lines
  • Pressure boxes in aluminum or steel
  • CNC loose pieces for breakaways on rods and air cylinders
  • CNC
  • Manual

Part Length

  • 3-axis up to 98 in.
  • 5-axis up to 122 in.

Part Width

  • 3-axis up to 50 in.
  • 5-axis up to 61 in.

Part Height

  • 3-axis up to 26 in.
  • 5-axis up to 36 in.

Part Weight

  • Up to 2500 lbs.

Tolerances (+/-)

  • .005 in CNC – Alum castings will vary
  • 2 to 8 weeks
  • MasterCAM
  • IGES
  • STEP
  • AutoCAD (DXF, DWG)
  • Parasolid (X_T, X_B)
  • Medical
  • Automotive
  • Aerospace
  • Packaging
  • POP displays
  • Shipping pallets and trays
  • Inspection
  • Job Number / paperwork
  • Instrument certifications
  • FARO ARM Laser CMM available
  • Vacuum forming sample parts up to 4′ x 6′
  • Design
  • Engineering
  • CAD / CAM
  • Reverse engineering
  • Testing
  • Mold repair

Pressure Form Vacuum Molding vs Injection Molding


Pressure Form Vacuum Molding involves heating a plastic sheet until it’s pliable, then using a vacuum to suck it down onto a mold. The plastic cools and solidifies, forming the shape of the mold.

Types of Parts Made: 

  • Large, thin-walled parts
  • Parts with fine details on the mold-facing side
  • Components like dashboards, refrigerator liners, and trays


  • Cost-effective for large parts
  • Lower tooling costs compared to injection molding
  • Capable of producing large parts with less material waste
  • Excellent for making parts with clear materials


  • Limited to relatively simple geometries
  • Only one side of the part has a finished surface

During the Injection Molding process, molten plastic is injected under high pressure into a mold. This technique is known for its precision and ability to create complex geometries.

Types of Parts Made:

  • Small to medium-sized parts with complex geometries
  • High-volume products like bottle caps and automotive parts
  • Components requiring tight tolerances and intricate details.


  • High production rates and efficiency
  • Dimensional control for complex parts
  • Wide range of material choices and colors
  • Good strength and surface finish on all sides of the part


  • Higher tooling costs and longer lead times
  • Not cost-effective for small production runs

To summarize, Pressure Form Vacuum Molding is more suited for larger, simpler parts with a focus on cost-effectiveness and material efficiency, especially for clear or thin-walled components. Injection molding, on the other hand, is better suited for producing small to medium complex parts with high precision and strength, but at a higher cost and tooling investment.

As a mold manufacturer for pressure form vacuum molding, our expertise lies in providing cost-effective solutions for large-scale, simpler geometries, ensuring quality production with minimal material waste.

Custom & Added Value Services


Looking for that one company that can provide you with Custom Dies, and one that also has the capabilities to handle your projects from start to finish? We are Borke MS and we have the expertise to handle just about any Custom CNC Machined Pattern & Fixture project. We specialize in design-part and tooling, CAD/CAM, reverse engineering, mold testing and repair, etc.


We also offer superior materials to create Pressure Boxes and Plug Assist of the highest qualities and greatest tolerances in the industry. No matter what the design need is, Borke MS specialist are here to assist you from concept to completion. Regardless of the complexity and size of your project, we have to capabilities to see it through.

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