Infinite Shapes and Shape Copier

Infinite Shapes is a how-to guide for thermoforming plastic parts and a building manual for a bolt together Shape Copier vacuum forming machine.

The focus of this manual is practical, affordable thermoforming technology for small companies.

Thermoforming can produce complex, highly detailed parts. A wide range of plastic materials can be thermoformed.

Companies making plastic products inhouse can reduce costs, assure quality control, and maintain a smaller inventory.

Infinite Shapes will explain how vacuum forming machines work, how to use shape forming techniques, how to make wood and epoxy molds, and how to select plastics for shape forming.

Rapid prototyping thermoforming using inexpensive and easy to modify wood molds can reduce new product development time and cost.

Prototype molds can be converted to long lasting epoxy molds for production.

Shape Copier

The Shape Copier is assembled from pre-cut, drilled, and tapped T-slot aluminum extrusions that are available from several suppliers for bolt together assembly.

The typical cost for a commercially built thermoforming machine is two to three times the cost of parts. Assembling a Shape Copier can greatly reduce a machine’s cost.

The Shape Copier is easy to operate and can form a wide range of high quality products. The Shape Copier is relatively simple, but commercially competitive.

This manual contains step-by-step assembly drawings, pictures, and instructions needed to build a Shape Copier. A complete parts and materials list with part specifications and supplier contact information is provided.

Examples of Commonly Thermoformed Products
Marketing                               Industrial
Display Cases                         Machine Guards
Point of Sale Displays             Pallets
3-D Signs                                Tote Bins
Neon Sign Housings               Tool Cases
Cosmetics Cases                     Instrument Case
Packaging                                Machine Housings
Home                                      Medical  
Skylights                                  Equipment Housings
Refrigerator Door Liners          Prostheses
Garage Door Panels                Contoured Patient Supports
Drawer Liners                          Packaging
Sandboxes                               Vehicles     
Planters                                   Aircraft Wall Panels
Cups                                        Instruments Panels
Decorative Ceiling Panels       Truck Bed Panels
Decorative Wall Panels           Tractor Shrouds
Luggage                                   RV Side Storage Bins
Food Containers                      Rv Exterior Components

Sample of parts a Shape Copier can thermoform.