As the famous 80’s song goes, when things are "under pressure" they tend to change. But while pressure can so frequently be seen as a negative thing, it doesn’t have to always be thought about that way. Pressure is used as a positive force more frequently than you may think. Consider for example pressure forming. While you may hardly (or never) think about pressure forming, it has undoubtedly had an impact on your lift, whether you know it or not.

So, what is it?

Pressure forming is a manufacturing process that is frequently used to form plastics into a pre-determined shape. Think about all of the plastic products you use every day. From the reusable containers arranged haphazardly in your pantry and the plastic packaging in your medicine cabinet to the speakers on your desk and even the plastic interior of your car, pressure forming may have very well been the manufacturing process that made it all possible.

With pressure forming, a heated plastic sheet (thick or thin, we’ll get to that later) is forced against a typically concave mold. Then, compressed air is forced into the heated sheet, forcing it to form to the shape of the mold.

While closely related to vacuum forming, pressure forming is capable of producing more pressure than vacuum forming, which enables the process to achieve the greater level of detail so many manufactures use it for. By increasing the level of air pressure pumped into the mold, the manufacturer is able to achieve an almost limitless combination of shapes and sizes, while simultaneously being capable of providing intricate patterns, details, grooves, and textures.

In addition to being capable of extreme detail, pressure forming can also create undercuts and sharp edges when a product calls for it. This capability lowers tooling costs, speeds up manufacturing, and makes the entire manufacturing more efficient. mirroring the capabilities of some more expensive processes such as injection molding and foam molding.

In addition to the already mentioned ability to provide sharp edges, lower tooling costs, and greater detail, pressure forming also allows the incorporation of logos and lettering on the surface of a part or product. Ultimately, while pressure forming is generally more expensive than vacuum forming, it remains a popular manufacturing process specifically due to its ability to produce almost identical results as injection molding, at a much lower cost.