Violet Fox: Vacuum Forming Box Instruction Manual

ID Number Component Name

1 Upper Frame
2 Plastic Sheet
3 Lower Frame
4 Binder Clip
5 Vacuum Box Lid
6 Vacuum Box Body
7 Vacuum Attachment – Dyson DC35
8 Vacuum Attachment – Generic
Preliminary Instructions To complete this project you will require:
• 3D filament 120grams (0.26lb)
• 4 x binder clips
• 2 x wood or MDF sheets 100mm x 155mm x < 5mm (L x W
x H)
• HPDE plastic sheet from a milk/juice container 100mm x
155mm (L x W)
• Wood/MDF cutting tools
• Vacuum cleaner
• Oven or heat gun
• Heat resistant gloves
• Safety glasses
• Particle/dust respirator
Step 1
Note
You only need to 3D print one vacuum attachment. Most vacuums
will fit the Generic Vacuum Attachment. If you have a Dyson DC35
3D print the Vacuum Attachment – DC35 part.

3D print the Upper/Lower Frame Template, Vacuum Box Lid, Body,

and the applicable Vacuum Attachment. If you are using the Dyson
DC35 Vacuum Attachment, position the locating key at the 12
o'clock position (position marked with red arrow in the diagram on
the left).
Gently press the Vacuum Attachment piece into the Vacuum Box
Body; the snap lock clips will hold the two parts together.
Insert the Vacuum Box Lid into the Vacuum Box Body.
Attach the vacuum to the Vacuum Attachment piece.
Place the part/s you want to vacuum mold on the top of the Vacuum
Box Lid.
Step 2
Caution
Wood and MDF dust particles can be hazardous. When cutting
MDF/wood wear the applicable protective equipment e.g. glasses
and particle/dust respirator.

Trace the Upper/Lower Frame Template onto the two pieces of

MDF/Wood. Using cutting tools, remove the inner body; the finished
MDF/wood piece will look the same as the Frame Template.

Step 3

Cut up the HPDE sheet to the outside dimensions of the

Upper/Lower Frame Template, 100mm x 155mm (L x W).
Remove any glue and/or labels from the HDPE sheet.
Mount the HDPE sheet between the Upper and Lower Frames.
Secure the three parts together using a binder clip on each side.
Step 4

Caution
Heat the HPDE sheet on a heat resistant surface. Use heat resistant
gloves to handle the Upper/Lower Frame Assembly

Evenly heat the HDPE sheet using the oven or heat gun until the
sheet droops and its transparency changes from its original slightly
white colour to transparent.
Turn off the heat gun/oven.

Step 5
Note
For best results ensure that the object that is to be molded is warm.

Quickly place the Upper/Lower Frame Assembly over the top of the
Vacuum Box Assembly and lower the frame down over the object to
be molded.
Turn on the vacuum and operate it until the HDPE plastic is tightly
molded onto the object, typically only a few seconds.
Turn off the vacuum.
Remove the molded object from the HDPE plastic.