At FB-AVAK we have over 50 years experience in producing high-quality vacuum-formed components and assemblies, delivering engineered solutions to a broad range of industries.
We partner closely with clients to bring concepts to life – whether prototypes, one-off components, or full-scale production runs.
Do you have a project in mind and you’re not sure if its suitable for vacuum forming? Simply call us, we’re happy to talk it through: 01420 477411
With comparitively low tooling costs, vacuum forming at FB-AVAK offers unmatched flexibility and economy, making it ideal for product development and prototyping. It is also a competitive mid- to long-run manufacturing solution for a wide range of components and enclosures.
We offer support for your project, where required, with input from our experienced staff from the early stage of development through to final production, helping you avoid common mistakes and time-consuming re-work.
Our processes enable us to competitively produce one-off’s, small batch production for commercial evaluation, through to multi-impression tooling and relatively high volume output.
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AUTOMOTIVE
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MOTORSPORT
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INDUSTRIAL
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ELECTRICAL
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HEATING & VENTILATION
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MATERIALS HANDLING
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MEDICAL
From CAD to Completed Component: The FB-AVAK Manufacturing Workflow
At FB-AVAK, we provide a fully integrated vacuum forming manufacturing process, transforming your concept into a finished, production-ready component with precision, efficiency and scalability.
Every project begins with data. We work directly from your original CAD files, optimising designs for vacuum forming to ensure correct draft angles, material behaviour and tooling strategy. Where CAD data is unavailable, we are able to reverse engineer existing components and generate accurate digital models for redevelopment or repeat production.
Using advanced 3- and 5-axis CNC machining, we manufacture high-precision vacuum forming tools from model board, resin or aluminium, depending on volume and performance requirements. Heated thermoplastic sheet is then formed over the tool using controlled vacuum pressure, producing lightweight, durable components with consistent surface quality and dimensional accuracy.
Once moulded, parts are trimmed and detailed using precision 5-axis CNC finishing, ensuring repeatable accuracy across every batch. This process guarantees clean edges, accurate cut-outs and reliable fit within larger assemblies.
From here, customers can choose the most efficient supply route. Components can be shipped directly, stored for scheduled draw-down, or integrated into fully assembled units alongside fixings, metalwork, electronics or other sub-components.
By combining CAD expertise, precision CNC tooling, scalable vacuum forming and in-house assembly, FB-AVAK delivers a seamless end-to-end manufacturing solution—reducing lead times, improving consistency and helping customers bring high-quality products to market with confidence.
Find out more about the vacuum forming process