Custom Vacuum Formed Plastic Parts & Panels
Perspex Online offers professional vacuum forming services for a wide range of industries and applications. Backed by the fabrication expertise of P & M Plastics, our vacuum…
Expert Estimation Services
Upload your technical drawings (DXF, PDF, or STEP) for a comprehensive quote within 4 business hours.
Engineering Review
Every drawing is audited by our senior engineers for manufacturability and cost-efficiency.
Australia-Wide Shipping
Secure, tracked logistics for precision components delivered across Australia.
Precision Machining
State-of-the-art CNC and laser technology ensuring tolerances up to ±0.1mm.
Technical Material Library
Specialised polymers for industrial, chemical, and retail applications.
Precision Workflow
Our quality assurance pipeline ensures every component meets your exact engineering requirements.
Submit Your Enquiry
Send us your drawings, sketches, or part idea and we'll assess the best material, thickness, and forming method for your application.
Confirm Tooling & Material
We prepare or recommend suitable moulds and confirm the plastic material - such as ABS, PETG, or Polycarbonate - based on your functional and aesthetic requirements.
Form & Finish
Your sheet is heated and drawn over the mould under vacuum pressure, then trimmed, CNC-finished, and inspected for quality and dimensional accuracy.
Collect or Receive Delivery
Finished parts are packaged carefully and made available for pick-up from our Melbourne facility or dispatched via nationwide freight.
Engineering Standards & Fabrication Capabilities
When Vacuum Forming Is the Right Process
Vacuum forming suits projects where you need a three-dimensional plastic part produced from sheet material without the tooling cost of injection moulding. It's the preferred process for short to medium production runs, prototypes, and parts where geometry is relatively consistent in wall thickness.
If your application involves enclosures, trays, covers, liners, or display components - and you need repeatable output at a manageable unit cost - vacuum forming is typically the most practical route.
Industries and Applications We Form Parts For
Perspex Online handles vacuum forming across a broad range of commercial and industrial sectors. The process is well suited anywhere a lightweight, rigid formed shell or tray is required at volume.
- Packaging: product trays, blister backing panels, and protective inserts
- Automotive: interior trim components, covers, and housings
- Point-of-sale and signage: display risers, light diffuser covers, and shaped headers
- Medical and hygiene: formed equipment guards and sterile tray liners
- Electronics: enclosures and EMI shield housings
- Industrial: machine guards , ducting covers, and panel fascias
Material Selection for Formed Parts
The material you choose directly affects impact resistance, surface finish, chemical tolerance, and whether the part can be painted or bonded afterward. Common choices include ABS for structural rigidity and paintability, polycarbonate where optical clarity or high impact strength is critical, and acrylic where surface appearance and UV stability matter most.
Perspex Online stocks forming-grade sheet in a range of thicknesses across all supported materials, so material selection is part of the quoting conversation - not an afterthought.
Backed by a Full Fabrication Workshop
Vacuum forming at Perspex Online is supported by the full workshop capability of P&M Plastics, meaning formed parts can be CNC trimmed, routed, laser cut , or machined to final specification without leaving the facility. This matters when your part needs accurate cut-outs, bonded assemblies, or secondary finishing that most standalone forming operations would outsource.
From mould preparation through to final inspection and despatch, the entire process runs under one roof - giving you tighter control over lead times, tolerances, and communication throughout the job.
Project Gallery
Why Choose This Service
Materials We Process
Capabilities
Vacuum Forming FAQ
What is vacuum forming?
What materials can be vacuum formed?
What size parts can you vacuum form?
Do you make the moulds in-house?
What is the minimum order for vacuum formed parts?
Applications for Vacuum Forming
Acrylic Domes
Thermoformed and machined tube for dome covers and display bubbles.
Solar Battery Covers
Weatherproof plastic covers for home battery storage and inverter units. UV-stable HDPE and polycarbonate, cut and vacuum-formed to size.
Dust Covers
Clear tube covers for equipment, instruments, and display protection.
Machine Guards
Impact-resistant clear and solid sheet guards for CNC, lathes, and production lines.
Air Conditioner Covers
Custom cut acrylic, polycarbonate and HDPE air conditioner covers. Screen outdoor units, protect from weather and keep airflow clear. Cut to size, shipped Australia-wide.
Heat Pump Covers
Weatherproof acrylic, polycarbonate and HDPE covers for heat pump hot water units. Screen the unit, protect it from weather, keep vents clear. Cut to size.
Boat Window Replacements
Clear Perspex replacements for boat windows, windscreens, and portholes.
Caravan Window Replacements
Replace foggy, cracked or crazed caravan windows with cut-to-size acrylic or polycarbonate glazing. UV-stable, lightweight and precision-cut Australia-wide.
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Read guide →Ready to start your project?
Join thousands of businesses across Australia who trust Perspex Online for precision plastic fabrication.