【Vacuum Forming Application】From Scratch to Small-Batch Production in Just One Day for Stationery Design?
A stationery product line, from concept to completion, in just one day? Prototype design, blister packaging, all processes handled by one machine! Even working alone in a studio, it's manageable. Find out how:
London industrial designer Charlie Humble Thomas has collaborated with major corporations and educational institutions such as MUJI, Samsung, and Honda, designing prototypes for various fields. He is also an independent product designer, developing his own range of products.
This time, Charlie was tasked with designing a set of stationery for a home goods company, with the requirement for small-batch production in a short timeframe. The product design and development process, from initial concept to aesthetic design, testing, and idea validation, is indispensable at every stage. It also had to meet the client's various demands for details and materials. Completing this independently within a limited time was an extremely challenging task!
Charlie designed a "business card holder" with dense ridge patterns. First, he used a laser cutter to cut easily accessible materials (such as wood, cardboard, rubber), and then glued the cut pieces together. The delicate stepped texture was created effortlessly! After completing the initial shape design, the object was placed into a vacuum forming machine, paired with vacuum forming sheets, and pressed down for 3 seconds to form the object's exterior.
After demolding, a delicate mold is immediately obtained, which can then be filled with casting materials such as concrete or plaster, and can also be mixed with different colors according to various preferences.
Charlie enjoys creating with a hands-on approach combined with the latest technology, constantly seeking innovative production methods in every attempt: "I use the FormBox vacuum former with a laser cutter to quickly transform abstract ideas into physical objects. It's a super practical machine for realizing designs!" Charlie enthusiastically stated.
The FormBox vacuum forming sheets can be reused. After the initial design process is approved by the client, Charlie only needs to repeatedly fill the molds to quickly and consistently complete small-batch production, even by himself. Not only that, but after the products are made, the FormBox can also be used to produce blister packaging, handling all product development processes with one machine!
(Image source: The Dots design website, Charlie Humble Thomas's section)
Typically, outsourced manufacturers use industrial equipment for processes like cutting and drilling. From sample production to batch production, this tends to incur higher time and cost expenditures.
(Cost comparison: Using the Mayku FormBox vacuum former versus outsourced manufacturing.)
Design sketches turned into physical products and successfully small-batch produced within a day, not only saving a significant amount of time and money in prototype creation; the compact desktop equipment allowed all production processes to be completed in Charlie's personal studio! Did you enjoy this sharing? 3dmart not only offers 3D printing services, but also provides more information and application cases for the FormBox vacuum former and laser cutter. Contact us now to learn more.
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