Vacuum Formed vs Injection Case
Vacuum forming and injection molding are two methods for plastic case production. Vacuum forming is lower-cost, faster tooling, good for low-to-mid volume. Injection molding is higher cost, slower tooling, good for high volume and complex features.
Detailed Comparison
| Aspect | Vacuum Formed | Injection |
|---|---|---|
| Tooling cost | $3,000-15,000 | $30,000-200,000+ |
| Lead time (tooling) | 2-4 weeks | 8-16 weeks |
| Min order quantity | 100-500 pcs | 1,000-10,000+ pcs |
| Per-unit cost (high vol) | $20-50 | $5-20 |
| Wall thickness | 1.5-6mm (uniform) | 1-15mm (variable) |
| Detail level | Moderate | High (inserts, threads) |
| Material | ABS, HIPS, PVC, PETG | PP, ABS, PC, PA, PC/ABS |
| Best for | Low-mid volume, prototypes, custom colors | High volume, OEM, complex features |
Verdict
Choose vacuum forming for: prototypes, low-volume production, custom colors, short lead time. Choose injection molding for: high volume (1,000+), complex features, OEM, lower per-unit cost at scale.
Which is cheaper for 500 pieces?
Vacuum forming is significantly cheaper for 500 pieces due to lower tooling cost. Injection molding becomes cheaper at 5,000+ pieces per SKU due to lower per-unit cost.