真空成型原理與技術解析Thermoforming Process & Mold Engineering
真空成型原理Thermoforming Process Principle
真空成型係將熱塑性塑膠板材或卷料加熱軟化後，將模具與材料間抽真空，利用大氣壓力使材料緊密服貼於模具表面，隨後經由風冷或水冷冷卻定型，最後吹氣脫模，即完成初步成型。 Thermoforming involves heating a thermoplastic sheet until pliable , then drawing a vacuum between the sheet and the mold so atmospheric pressure forces the sheet onto the mold surface. Once cooled by air or water, air is blown to release the finished part.
成型後需進行後加工及裁切，常見如：沖床沖壓（適用於立體造型邊緣）、雷射刀模沖切（裁切平面外框與蝴蝶洞）、熱封/高週波黏合、網版印刷與折邊加工。 Post-processing options include hydraulic press trimming, steel rule die cutting, heat/high-frequency sealing, silk-screen printing, and edge folding.
真空成型特性說明Technical Characteristics
- 厚度變化Thickness Variation： 材料經拉伸後，各處厚度不均勻，拉伸高度越高之處壁厚越薄，最大厚度不超過原始板材厚度。 Sheet stretching causes non-uniform wall thickness; deeper draws result in thinner walls.
- 轉角 R 角Corner Radius (R-Corner)： 受到材料覆蓋與拉伸限制，造型轉折處必然呈現 R 角，無法做到極致尖角。 Material stretch constraints necessitate rounded corners rather than sharp 90-degree angles.
- 開發成本優勢Cost-Effective Tooling： 相較於射出成型模具，真空成型模具開發費用極低，特別適合中大量及客製化生產。 Tooling costs are significantly lower than injection molds, making it ideal for medium-to-large custom runs.
常用塑膠材質特性比較表 Plastic Material Comparison Table
| 材質名稱Material | 回收編號RIC Code | 耐溫極限Temp Limit | 特點與高週波適性Features & Sealing | 主要應用領域Primary Applications |
|---|---|---|---|---|
| PET | 1 | 60°C | 高透明、黑色、白色。高週波需選用 PETG。具備食品、抗靜電、內含抗靜電、導電、醫療、耐衝擊等級。 High transparency、 Black、 White. Food grade, ESD anti-static, conductive, medical ,Impact resistance grades available. | 電子 Tray、食品盒、自動化工作盤、醫療包裝、賣場雙泡殼（逐步取代 PVC）、五金零件包裝、折邊泡殼、高週波泡殼。 Electronics trays, automated assembly trays, food boxes, medical packaging, clamshells, hardware packaging. |
| PVC | 3 | 60°C | 高透明，可直接高週波。有耐衝擊等級。目前使用量漸減，多改由 PET 取代。High clarity, excellent high-frequency sealing. Impact resistance grades available. Gradually replaced by PET. | 五金零件包裝、折邊泡殼、高週波泡殼。Hardware parts packaging, slide blisters, high-frequency sealed blisters. |
| PP | 5 | 120°C | 乳白色（可調各種顏色），耐高溫可微波。可做抗靜電、導電等級。Translucent/colored, microwaveable, high heat resistance. ESD options available. | 食品容器、需高溫殺菌或耐熱之零件包裝盤、五金工具內襯。Food containers, autoclavable medical trays, heat-resistant component trays, tool box inserts. |
| PS | 6 | 80°C | 常用黑色、白色（可調各種顏色）。表面可做平面、花紋、亮面、霧面處理。具有抗靜電與導電材料等級。 Commonly black, White.Surface Finishes: Smooth, Textured, Glossy, Matte. Widely used for electronic ESD anti-static and conductive trays. | 電子產業零件 Tray 盤、自動化工作盤、五金工具內襯。Electronic component trays, automated assembly trays, tool box inserts. |
| ABS | - | 85°C | 特性與 PS 相近，但韌性與耐衝擊強度更強。常用黑色、白色（可調各種顏色）。表面可做平面、花紋、亮面、霧面處理。具備防火、抗靜電、導電等級。 High impact resistance and toughness compared to PS.Commonly black, White.Surface Finishes: Smooth, Textured, Glossy, Matte. Flame-retardant , ESD anti-static, conductive grades available | 高強度電子周轉盤、五金工具內襯。Heavy-duty industrial transport trays, automotive parts carriers, tool box inserts. |
真空成型模具製造工藝Mold Tooling Technologies
CNC 精密切削鋁模CNC Machined Aluminum Molds
直接採用一整塊高品質鋁合金原料，透過 CNC 數值控制铣床直接切削成型。優點為尺寸精度極高、表面光滑、風路設計精細，適合高精度的電子 Tray 盤與醫療包裝模具。 Directly carved from solid high-grade aluminum blocks via CNC milling. Provides superior dimensional accuracy, smooth surface finish, and optimized vacuum venting for precision electronics and medical trays.
翻砂鑄造鋁模Cast Aluminum Molds
先以木材、代木、石膏或電木製作原型模型，再進行翻砂鑄造成鋁模，最後經過拋光與建立風路。適合成本控管、造型較大或一般賣場包裝模具。 Created by sand casting aluminum from wood or tooling board patterns, followed by hand polishing and vent hole drilling. Cost-effective for large retail blisters.