Custom vacuum-formed tanks for marine research

Challenge

A marine research organisation needed specialised rectangular tanks with precise internal dimensions (180mm x 125mm x 75mm deep). The solution required quick development and reliable performance in marine environments, with the potential for future manufacturing in fluoropolymer materials.

Technical Complexities

The project presented several challenges:

•   Large profile dimensions risked material thinning during vacuum forming

•   Corners and edges were vulnerable to splits, cracks and pin holes

•   Prototype validation was needed before using expensive fluoropolymer materials

•   Future transition from PVC to FEP would require different forming parameters

•   Small production quantities made conventional tooling cost-prohibitive

Solution

Our R&D team developed these specialised tanks using a 0.5mm PVC sheet for initial prototyping, allowing cost-effective concept validation and tooling refinement. Key design modifications included rounded corners to reduce stress concentration.

The fabrication utilised our bespoke vacuum forming equipment, designed and built in-house. This proprietary technology-enabled rapid iterations and real-time adjustments—capabilities not possible with standard commercial equipment.

Throughout development, the team monitored material distribution, particularly in corners and vertical walls where thinning presented the highest risk.

Results

The project delivered excellent outcomes:

•   Successful production of prototype tanks meeting exact dimensional requirements

•   PVC prototypes demonstrated structural integrity with no defects

•   A clear pathway established for transitioning to FEP material in future phases

•   The client received functional prototypes quickly and cost-effectively

This case demonstrates our capabilities in vacuum forming technical polymers, custom tooling development, and collaborative problem-solving for specialised research applications.

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