Custom Vacuum Formed Tray

This project involved designing and fabricating a custom vacuum-formed tray to securely hold an adjustable wrench. The process combined CAD modeling, laser cutting, and vacuum forming to create a precise, functional storage solution.

The design process began by photographing the tool and importing the image into SolidWorks, where I traced its outline and converted it into a DXF file for laser cutting. The mold was constructed from multiple layers of 3mm acrylic, carefully glued together to achieve the desired height. Vent holes were strategically placed along the perimeter to ensure proper airflow during the vacuum forming process, optimizing the mold’s ability to capture fine details.

Once assembled, the mold was placed into a vacuum forming machine, where a 200mm x 200mm sheet of thermoforming plastic was heated and pressed over the mold under vacuum pressure, shaping it to the precise contours of the wrench. After cooling, the part was trimmed to remove excess material, resulting in a clean and professional final product.

This project strengthened my skills in CAD design, digital fabrication, and manufacturing techniques such as laser cutting and vacuum forming. It also reinforced the importance of efficient prototyping and iterative design, key principles in product development and packaging design. By leveraging vacuum forming, I demonstrated how rapid and cost-effective tooling can support dynamic industries where adaptability is essential.