Vacuum Former/Tray

Instructions

**This is still experimental, and many steps were done on the tool rather than in the SVG since I was still figuring it all out as I went** https://community.shapertools.com/t/vacuum-former/5764/4 This is designed to be used with the ShaperOrigin Vacuum hose, and an appropriate heat source (oven, hot box, etc.) I handled most of the tricky parts on the tool whole cutting, so I would recommend taking your time, and thinking things through as you go. Frame and Tray (1/4" material) 1. Using the 1/8 in bit cut out the holes (inside cuts) for only 1 of the 2 trays needed. This takes a while get comfortable. I had to change the cuts on the tool sorry. 2. Cut the inside of the frame using a 1/8" bit to separate the tray from the frame. Do this twice. 3. Outside cut using 1/4" bit. Base Top (1.5" material) **Note: I oriented the part so the hose hole is near the top as you are working on the part. 4. Starting with the top, inside cut the center (for the vacuum tray) leaving a 1/4" offset. The hole is sized the same as the tray, so the offset assumes a 1/8" overlap from the tray cut in step 2. You will need the offset to keep the top from falling into the hole. Final cut depth should be 3/4" in multiple passes. 5. Cut the inside and outside rings for the hose to a depth of .4". The goal is to get a snug fit for the vacuum hose, so start with an offset and slowly reduce the offset until you have the correct fit. 6. Cut the inside diameter of the hole for the vacuum leaving an offset for the wall thickness your material can handle. I used a .2" inside offset, but this may vary by your material. Cut to a depth of 3/4" 7. Cut the outside perimeter of the frame to 1/4" dept. 8. I then rough cut the strait edge opposite the vacuum hose hole, and the sides next to it using the jigsaw, but did not remove the part from the rest of the stock. 9. Clean up 3 edges using the flush cut bit. Base back (same 1.5" material) 10. Flip the part over and snap a grid using 2 smooth edges, and place the part at 0,0 with the hose hole lined up appropriately with the reverse side. 11. Inside cut the center with a 1/8" offset to a depth of 3/4". The middle should be cut all the way through now. Alternatively, you can pilot hole in the middle with a drill, jigsaw out the center, and flush cut the inside edge. 12. Cut the reverse side of the top hole for the vacuum hose to a depth of 3/4" using the same offset as the you used above, or cut using an appropriate forstner bit from the top side down. 13. Inside cut offset from the Outside edge to make the channel for the air, see picture. I don't remember the exact offset, but you just need to clear the airway to a depth of 1/2-3/4" 14. Glue a piece of 1/4" sheet material to the back, and flush cut with trim router. 15. I ran a bead of hot glue around the inside edge to seal it well. 16. Glue top tray into place.