Do-it-yourself vacuum press for pumping air at home

Opening a small furniture manufacturing enterprise begins with the acquisition of the necessary equipment.

It’s good if you have the opportunity to purchase branded factory-made machines.

But what if the starting capital is very limited?

There is only one way out - to assemble some of the units yourself. You can, for example, make a vacuum press with your own hands.

Application

When making furniture, parts made from particle boards, for example MDF, are covered with PVC film. It is also used to cover door trims. Such cladding has an attractive appearance at a low cost. But covering wood with film is not at all as simple a task as, for example, gluing wallpaper. A special device called a vacuum press is required.

This machine consists of the following components:

1. The bed is the base on which all the elements are assembled.
2. Vacuum chamber. A durable box with an open top into which the workpieces are placed. Then it is covered with PVC film.
3. A heating element (thermal module), through which the film is heated to the required temperature.
4. Vacuum system – pump with additional equipment. These components are designed to pump air out of the vacuum chamber.
5. A cabinet in which the electrical circuit of the machine is assembled.

When the air is pumped out, the heated film fits around the parts coated with glue in a vacuum chamber, after which the coating can only be dried and trimmed here and there.

Vacuum press: purpose and principle of operation

Film furniture facades are widely used in the manufacture of cabinet or upholstered furniture due to the following characteristics:

• wide range of colors;
• variety of forms;
• affordable price.

Such facades are manufactured using special equipment , with the main production tool being a vacuum press. He places a PVC film on the surface of an MDF-based workpiece.

The press includes the following key elements:

• vacuum chamber or table;
• thermal module

The chamber most often has a rectangular shape and is made of a rigid material that does not compress under artificially created negative pressure from the inside. And on the outside, a PVC film is laid, the edges of which are sealed with the frame.

The film shrinking process includes the following steps:

• laying workpieces on the table;
• sealing;
• heating the films;
• air pumping;
• cooling;
• cutting out blanks and removing excess film from the facade.

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Model	Force, tn	Drive unit	Press dimensions, mm (HxWxD)	Press weight, kg	Bale size, mm (HxWxD)	Bale weight, kg	Loading window HxW, mm	Price in rubles, incl. VAT
GGP-4	4	1.5kW, 380V	2300x1000x600	450	700x750x500	40-60	500x750	115 721
PGP-4-1	4	2.2kW, 220V	2300x1000x600	450	700x750x500	40-60	500x750	131 701
GGP-5	5	1.5kW, 380V	2300x1000x600	460	700x750x500	40-80	500x750	126 411
PGP-5-1	5	2.2kW, 220V	2300x1000x600	460	700x750x500	40-80	500x750	140 408
GGP-6	6	2.2kW, 380V	2300x1200x700	510	700x900x600	60-100	500x900	135 558
PGP-6-1	6	2.2kW, 220V	2300x1200x700	510	700x900x600	60-100	500x900	148 673
GGP-7	7	2.2kW, 380V	2300x1200x700	510	700x900x600	60-110	500x900	142 171
PGP-7-1	7	2.2kW, 220V	2300x1200x700	510	700x900x600	60-110	500x900	152 751
GGP-8	8	1.5kW, 380V	2300x1000x600	450	700x750x500	40-110	500x750	133 795
GP-8-1	8	2.2kW, 220V	2300x1000x600	450	700x750x500	40-110	500x750	149 169
GGP-9	9	2.2kW, 380V	2300x1200x700	510	700x900x600	70-120	500x900	149 004
PGP-9-1	9	2.2kW, 220V	2300x1200x700	510	700x900x600	70-120	500x900	159 805
GGP-10	10	2.2kW, 380V	2300x1200x700	620	700x900x600	80-140	500x900	158 482
PGP-10-1	10	2.2kW, 220V	2300x1200x700	620	700x900x600	80-130	500x900	171 046
GGP-11	12	3kW, 380V	2100x1000x600	450	450x750x500	40-80	400x750	170 385
PGP-11-2	15	3kW, 380V	2100x1000x600	450	450x750x500	40-100	400x750	172 148
PGP-12 (R)	12	3kW, 380V	3000x1650x900	1050	900x1050x750	80-280	550x1100	196 725
PGP-12-1(R)	12	2.2kW, 220V	3000x1650x900	1050	900x1050x750	80-280	550x1100	224 277
GGP-15 (R)	15	3kW, 380V	3000x1650x900	1050	900x1050x750	100-320	550x1100	205 982
PGP-15-1 (R)	15	2.2kW, 220V	3000x1650x900	1050	900x1050x750	100-320	550x1100	231 551
GGP-15 (RS) (36 sec)	15	3kW, 380V	3000x1650x900	1050	900x1050x750	100-320	550x1100	211 047
PGP-12 MU	12	3kW, 380V	2700x1300x800	800	800x1100x700	100-300	450x1050	188 900
PGP-12-1 MU	12	2.2kW, 220V	2700x1300x800	800	800x1100x700	100-300	450x1050	208 958
PGP-15 MU	15	3kW, 380V	2700x1300x800	800	800x1100x700	100-350	450x1050	190 333
PGP-15-1 MU	15	2.2kW, 220V	2700x1300x800	800	800x1100x700	100-350	450x1050	210 281
PGP-15 ICC (36 sec)	15	3kW, 380V	2700x1300x800	800	800x1100x700	100-350	450x1050	198 687
PGP-12 M	15	3kW, 380V	3000x1400x900	900	800x1100x700	100-280	550x1100	194 410
PGP-12-1 M	15	2.2kW, 220V	3000x1400x900	900	800x1100x700	100-280	550x1100	220 971
PGP-15 M	15	3kW, 380V	3000x1400x900	900	800x1100x700	150-320	550x1100	202 676
GGP-15-1 M	15	2.2kW, 220V	3000x1400x900	900	800x1100x700	150-320	550x1100	227 804
PGP-15 MS (36 sec)	15	3kW, 380V	3000x1400x900	900	800x1100x700	150-320	550x1100	217 279
PGP-16-2	15	3kW, 380V	2700x1000x600	500	500x750x500	40-150	600x750	179 312
PGP-18B	18	4kW, 380V	3200x800x850	1050	—	—	1350x800	273 600
PGP-18BU	18	4kW, 380V	3200x800x850	1100	800x800x750	—	550x800	295 250
PGP-20 M	20	4kW, 380V	3000x1400x900	950	900x1100x750	100-300	550x1100	202 511
PGP-20 (R)	20	4kW, 380V	3000x1650x900	1100	900x1050x750	100-300	550x1100	209 399
PGP-24 (RSh)	24	5.5kW, 380V	3100x1650x900	1300	900x1050x750	100-500	600x1100	272 494
PGP-30 (RSh)	30	7.5kW, 380V	3100x1650x900	1300	900x1050x750	100-700	600x1000	349 366
PGP-30TSh	30	7.5kW, 380V	3100x1400x950	1200	900x1100x750	300-450	600x1100	265 979
PGP-24 MSh	24	5.5kW, 380V	3100x1450x950	1200	900x1100x750	100-450	600x1100	260 316
PGP-30 MSh	30	7.5kW, 380V	3100x1600x950	1200	900x1100x750	100-700	600x1000	335 598
PGP-24 MUSH	24	5.5kW, 380V	3000x1450x850	1000	900x1100x700	100-450	500x1100	243 013
PGP-30 MUSH	30	7.5kW, 380V	3000x1450x850	1100	900x1100x700	200-600	400x1100	306 714
PGP-45	45	7.5kW, 380V	3200x2000x900	2000	950x1060x750	300-600	500x1000	479 744

Materials for making a press

To manufacture the machine you will need the following materials:

bed

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Vacuum chamber

Vacuum system

Thermal module

Membrane vacuum press: types, principle of operation, DIY production

The furniture industry today is developing at a very active pace, which is associated with an increase in people's well-being and, accordingly, with an increase in demand for furniture that improves the quality of life and makes it more comfortable.

This, as well as the fact that modern consumers have become more demanding not only of the quality of furniture, but also of its decorative characteristics, has led to the fact that enterprises operating in this industry have become increasingly active in using innovative techniques and high-tech technologies in their production. equipment, one type of which is a vacuum press.

The vacuum press is used in the production of furniture facades, table tops, doors and for the production of decorative elements from acrylic or ABS plastic

The use of a vacuum machine and corresponding consumables makes it possible to provide furniture with completely unique decorative characteristics, which significantly increases the competitive advantages of the enterprise that uses this equipment in its production.

Operating principle

The main area of ​​application of vacuum presses is the furniture industry, where such equipment is used in the production of elements of cabinet and upholstered furniture - for gluing elements of furniture structures with PVC film and veneer, which perform primarily decorative functions. The tasks of the vacuum press in this case include depositing the film or veneer and ensuring their tight fit to the surface of the furniture structural element.

The principle by which a vacuum press works for veneering and covering furniture blanks with PVC film is quite simple. The heated film, which has become more plastic under the influence of the vacuum created under its surface, tightly fits the furniture piece, accurately repeating its configuration.

The film applied using vacuum technology to the surface of a piece of furniture made from MDF or chipboard lasts a very long time and does not contain even the smallest air bubbles.

The process of gluing a furniture element with PVC film using a vacuum press includes such technological operations as:

• laying furniture pieces on the equipment table;
• covering the workpieces with film and installing a pressure frame;
• sealing the vacuum chamber;
• heating the chamber and pumping air out of it;
• cooling of workpieces already covered with film;
• cutting the film along the contour of the blanks.

Design features

The vacuum press for furniture facades and other elements of its design consists of the following elements:

1. a vacuum table on the surface of which furniture pieces are laid (the surface of such a table must have high rigidity, so it is sheathed with sheet metal or thick tin);
2. a vacuum pump, the task of which is to pump out air from under the surface of the film for furniture blanks;
3. a clamping frame, which is also made of durable metal (the function of such a frame, equipped with reliable clamping elements, is to ensure the tightness of the air cavity under the film that covers the furniture blanks);
4. heating installation, which can be made on the basis of working elements of various types;
5. cover of a vacuum press, which can be hinged or roll-type.

Most models of vacuum presses are additionally equipped with one or more shafts installed at the end of the equipment. Such shafts, which make working on a vacuum press more convenient and reduce the time required to complete technological operations, are used to install rolls of film used for coating.

Many modern models of vacuum presses for MDF and chipboard can operate in automatic mode, which is ensured by CNC systems installed on such equipment.

The use of CNC vacuum presses is especially relevant for enterprises that produce furniture in series, when such equipment has to be used to cover many similar parts with film or veneer.

In such cases, CNC systems installed on such equipment make it possible to increase its productivity and, accordingly, reduce the cost of manufactured products. Industrial CNC membrane vacuum press with heated top and bottom platen

Main varieties

Today, two types of vacuum presses are produced:

1. conventional type equipment (such presses are used in cases where it is necessary to exert the most gentle influence on the workpiece, and are capable of creating a pressure whose value does not exceed 0.95 kg/cm2);
2. high-pressure vacuum presses (equipment of this type is capable of providing pressure up to 8.5 kg/cm2).

Equipment of the first type is used in cases where it is necessary to cover products with a simple configuration with PVC film or veneer.

Vacuum presses capable of creating high pressure are used for veneering or covering with PVC film parts of complex shapes.

In addition, such equipment is often used as a vacuum molder, with the help of which three-dimensional products of various configurations are made from sheet plastic.

The most common two layout options for vacuum presses are:

Purpose of the membrane in the design of a vacuum press

Both types of devices are equipped with a special membrane, so their more correct name is membrane-vacuum presses. Such an element of a vacuum press is used both when veneering elements of furniture structures and when covering them with PVC film.

In the first case, the membrane is necessary in order to increase the pressure exerted on the surface of the workpiece and the coating material during the process of joining them. In addition, when creating a veneer layer on the surface of a workpiece made of MDF or chipboard, the membrane prevents the coating material from shifting relative to the surface of the workpiece during the process of joining them.

When covering furniture pieces with too thin PVC films, the membrane protects them from the negative effects of high temperatures created in a vacuum chamber.

The membranes that vacuum presses are equipped with can be of two types: rubber and made of silicone. A more preferable option is silicone membranes, since they are more wear-resistant and allow you to cover even very small parts with PVC film.

Other Applications

In addition to gluing the surface of furniture structural elements with veneer and PVC film, a membrane vacuum press (MVP) can be successfully used to solve other problems, which, in particular, include:

• transfer of inscriptions and images to any surface using sublimation;
• formation of volumetric parts for various purposes from plastic sheets.

To transfer images from special paper to almost any (including embossed) surfaces using the sublimation method, equipment such as a thermal vacuum press is used.

Using a thermal vacuum membrane press, you can apply inscriptions and images to products made from ceramics, plastic, textiles and other materials. The principle on which a membrane vacuum heat press works is as follows.

• The product with a sheet of paper attached to it, from which an inscription or image needs to be transferred, is placed on the table of a vacuum press.
• The tight pressure of a sheet of paper with an image or inscription on the product is ensured by the press membrane, under which a vacuum is created.
• Under the press lid, after it is closed, a temperature is created, under the influence of which the image or inscription from the paper is transferred to the surface of the product.

Vacuum heat presses, presented on the modern market with a wide variety of models, are actively used by both large printing enterprises and small companies engaged in the production of souvenirs.

A vacuum molding press is used to produce relief-shaped products from sheet plastic.

Work order

The manufacture of a vacuum press is carried out as follows:

bed

The frame parts must be welded according to the drawing. Next, the seams are cleaned, the necessary holes are drilled, the rust is removed with a wire brush and the entire structure is primed for subsequent painting.

Homemade bed

Vacuum chamber

A stiffening frame should be welded from a 60x40 pipe, which will hold the bottom of the chamber (steel sheet 2 mm thick) from bending under the influence of atmospheric pressure.

Next, the bottom is welded to the frame, and the walls of the chamber are welded on top of it (a 60x40 pipe placed on the narrow side). The welds inside the chamber must be sealed (double penetration is recommended).

A part of the hinge with two eyes must be welded to one of the walls.

The clamping frame is made from the same profile and has the same dimensions as the vacuum chamber. The second part of the hinge is welded to it.

Membrane-vacuum chamber

To tightly compress the film with a clamping frame, eccentric clamps are used, which are made from a DN50 pipe, a rod with a diameter of 10 mm and a square pipe 20x20 mm.

If during the manufacture of the chamber its bottom has sagged, it can be filled with a self-leveling mixture (for example, based on epoxy resin) used for the manufacture of self-leveling floors.

The finished camera must be secured with 4 bolts on special frame supports. Next, you should install the eccentric clamps, assemble the clamping frame hinge and stick the seal.

Homemade press

Inside the chamber, over its entire area, an MDF platform is installed, consisting of 9 perforated rectangles with grooves cut on their surface (MDF sheet thickness is 10 mm). The parts to be processed will be placed on it. Thanks to this platform, air will be pumped out throughout the entire volume of the chamber evenly, regardless of the position of the parts being processed and the film.

Vacuum system

To pump air out of the vacuum chamber, it is recommended to equip the press with a liquid ring type pump (model VVN1-1.5-5.5). A check valve and a vacuum gauge must be embedded in the pipeline connecting the pump to the vacuum chamber. For reliability, you can also install a shut-off valve.

To operate the pump, you need clean water, free from mechanical impurities, for storage of which a steel tank with a volume of about 30 liters should be provided (you can weld it yourself from a steel sheet).

Vacuum pump

The pump must be installed in a strictly horizontal position (controlled by level) on a concrete base, and screwed with anchor bolts. In this case, it is necessary to build walls around the unit or place it in a recess, since water will flow out of it during operation.

Water is supplied from the tank to the pump and returned through two hoses, which must withstand temperatures of up to 100 degrees.

Water ring vacuum pump VVN1-6

All threaded connections in the vacuum pipeline must be sealed with FUM tape or similar material. To connect the pipeline to the vacuum chamber, a pipe is cut into the latter. It should be below the breathable platform and located in the middle of one of the walls. The pipeline is connected to the pump via a flange.

After assembling the machine, the vacuum system must be checked. The inlet of the vacuum pipeline inside the chamber is blocked with a piece of plywood, after which the pump is started. After 5 seconds, the vacuum gauge should show at least -0.85 atm.

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Thermal module

The thermal module frame is welded from a 20x20 pipe and is equipped with handles, as well as supports for attaching wheel axles (60x40 pipe).

The function of the wheels will be performed by type 6200 bearings.

The frame casing is made of steel sheet 0.5 mm thick with aluminum rivets.

Viewing windows measuring 40x20 cm should be cut in the side walls and tinted glass should be installed in them. Also, holes with a diameter of 50 mm with shutters must be drilled in the walls, through which it will be possible to measure the temperature of the film using a pyrometer.

Height-adjustable suspensions for KGT (quartz halogen thermal) lamps should be made from threaded rods, with insulating fiberglass plates with dimensions 40x20x2 mm secured to their ends. The pins are screwed into holes drilled in the thermal module cover. The lamps themselves are screwed to fiberglass plates with M5x20 bolts using Grover washers.

Power supply for the lamps (they are divided into several groups) is provided by RKGM wire in a heat-resistant sheath with TML type tips. Several wires from different groups are powered from a common bus in the distribution box, to which the power cable is supplied.

After manufacturing, the thermal module should be installed on rails welded to the frame.

Cabinet with electrical equipment

The 5.5 kW 3-phase vacuum pump motor is connected via a 3-pole circuit breaker and thermal relay.
For quartz heater lamps, the accuracy of the current strength is not particularly important, so there is no need to install a thermal relay.

To turn the pump on and off, a contactor with two non-locking buttons is installed on the operator console.

In the event of a power outage, the contactor is blocked and when the power supply is subsequently restored, the equipment will not start arbitrarily.

In the case of lamps, blocking during a power outage is not so critical, so they can be connected via a regular 2-position switch. The advantage of this option is the following: the controls for the pump and the thermal module will be very different, and it will be impossible to confuse them.

Application areas of vacuum forming technology

So, here are the main industries in which the vacuum forming method is used:

• Food industry – production of containers and containers for storage, warehousing, trays;
• Mechanical engineering – production of various plastic elements of the body, interior, engine compartment. The hot vacuum forming method is used to produce casings, air filter housings, and various elements of instrument panels;
• Medical industry - changing tables, bathtubs, carts for storing and transporting medicines and equipment, custom-shaped sinks, furniture elements and much more;
• Instrument making - instrument bodies, decorative elements;
• Production of equipment and finished products - housings and elements of various machines and finished products;
• Production of complex architectural decor and intermediate forms for casting plaster, concrete, metal;
• Production of advertising structures.

Almost all plastic products with a thickness of up to 10 mm are manufactured using hot vacuum molding. How does this happen?

Introduction

We made the first version of the body from glass mat and epoxy resin, this made it possible to evaluate the overall dimensions and appearance in real life. After making changes to the model, we began searching for possible low-cost technologies for manufacturing the case.

The body can be made by injection molding, but the cost of making the molds is a huge barrier for a startup. Therefore, for the manufacture of the upper part, it was decided to use thermo-vacuum molding. Vacuum forming of products is possible using inexpensive equipment and requires a small initial investment.

Why compact waste polymers?

Plastic polymers are a cheap and high-quality material for the production of many modern things. In connection with their massive use, the issue of disposal of such products has become acute .
Since the decomposition period of plastics is hundreds of years, without the widespread introduction of recycling technologies, very soon we could completely fill the planet with plastic bags and bottles.

To use plastic waste for subsequent production , you need :

• collect;
• sort;
• deliver to the processing site.

As a rule, products made from polymers have a small mass and a significant volume (bottles, film, boxes), so transporting them in their original condition is unprofitable .

Sorted waste must be turned into briquettes that are convenient for transportation . This can only be done with the appropriate press.

Therefore, this equipment is the first link in the technological chain of polymer recycling.

If the business produces a significant amount of plastic waste, namely:

• bottles;
• packages;
• boxes;
• films,

then their removal by public utilities costs a pretty penny.

But once you spend money on a press, you can, on the contrary, start making money by delivering polymer waste to recyclers, or at least significantly reduce the number of waste removal trips.

Also, collecting and recycling plastic waste can be an independent and quite profitable business .

Main formed materials

We chose a 4mm thick ABS sheet due to availability, this gives 2mm side walls when stretched, which is quite suitable for us.
In general, there is a huge amount of materials. Information from Wikipedia

Polymer material	ISO designation
Standard polystyrene	PS
Impact resistant polystyrene	SB, HIPS
Styrene-butadiene-styrene block copolymer	SBS
Oriented Polystyrene Sheet	OPS, BOPS
Foamed polystyrene sheet	EPS, XPS
Copolymer of styrene and acrylonitrile	SAN
Copolymer of acrylonitrile, polybutadiene and styrene (ABS plastic)	ABS
Copolymer of acrylic ester, styrene and acrylonitrile	A.S.A.
Unplasticized polyvinyl chloride	PVC-U
Plasticized polyvinyl chloride	PVC-P
Polyvinyl chloride foam sheet	EPVC
High Density Polyethylene	HDPE
Low density polyethylene	LDPE
Polyethylene foam sheet	EPE
Polypropylene	PP
Polypropylene foam sheet	EPP
Polymethyl methacrylate	PMMA
Polyoxymethylene, polyacetal	P.O.M.
Polycarbonate	PC
Polycarbonate Foam Sheet	EPC
Polyestercarbonate	PEC
Polyphenylene ether	PPE
Polyamide	PA
Polyethylene terephthalate	PET
PET, practically non-crystalline
PET, amorphous
PET, partially crystalline (nucleated) oriented polyethylene terephthalate sheet	(OPET)
Polyethylene terephthalate foam sheet	EPET
Polysulfone	PSU
Polyethersulfone	PES
Polyphenylene sulfide	P.P.S.
Acrylonitrile/methacrylate/butadiene copolymer	A/MMA/B
Cellulose acetate	C.A.
Cellulose acetobutyrate	CAB
Cellulose diacetate	(CdA)
Polyetherimide	P.E.I.
Thermoplastic elastomers (thermoplastic elastomers)	TPE
Thermoplastic polyolefin elastomer	TPO

Device

Photo of a vacuum press

A vacuum press consists of several main elements:

• Frame. Often this supporting structure is made in a collapsible type, which allows for repair, maintenance, disassembly for convenient transportation;
• Desktop. This is also a supporting structure, which is equipped with a special clamping frame;
• Vacuum system. This pneumatic system is the main element, without which it is difficult to imagine a vacuum press as such;
• Retractable carriage. There is a heating element here that is powered by electricity;
• Automatic control. Press vacuum drying chambers, doors, carriages, and the vacuum system itself operate using automatic controls. The operator's participation is minimal, which makes it possible to achieve higher quality artificial veneering, manufacturing elements for furniture facades, gluing plastic, chipboard, MDF, etc.

Photo of a vacuum press device, to create with your own hands

Vacuum press is classified according to several main characteristics. Let's start with the automation level. Depending on this characteristic, devices for pressing wood, facades, plastic, artificial stone are divided into two types.

1. Automatic. Here, the wood, artificial stone, and plastic presser performs all operations independently, so operator participation is practically not required.
2. Semi-automatic. These are more outdated models of wood pressing machines, since the operator must open the doors of the press chamber, press buttons to start, turn off, and remove compressed elements from wood, plastic, and MDF with his own hands. Their life is gradually coming to an end, since it is more efficient to work with devices where the mold operates in an accelerated automatic mode.

Vacuum system installation

Manufactured so that air can be pumped out. Thus, the film easily cover the surface of the workpiece. There are some points to consider when installing:

1. System components should not be custom-made; it is desirable that they can be purchased at retail.
2. It is best to select inexpensive components that have good reliability and ease of use.
3. The system must provide an air pumping speed and vacuum depth that will be sufficient to create typical flat facades and overlays.
4. The air outlet should not be dependent on the environment and the quality of the power supply.
5. The control functions should be simple and always inform about the pressure that the device provides, and they can also be used to regulate the speed of pumping out air.

The system must consist of several elements:

• liquid ring vacuum pump with water tank;
• pipeline for delivering air to the pump;
• tap and device to control pressure;
• the tabletop must pump out air from any point on the table, regardless of the position of the film and the workpiece.

Operating principle of a liquid ring pump

The impeller rotates in the direction of the arrow. Between the wheel hub, housing and water ring there is a working cavity, which is divided into cells by the wheel blades. When the pump operates, water is thrown away from the housing sleeve due to centrifugal force, and the volume of the cell increases and air begins to be sucked in. This volume will then decrease , and the gas will exit through the discharge window when clamped.

Only clean water must flow through the pump. This is necessary for heat removal to occur. Water is supplied to the central hole in the housing and discharged through a device that will separate the gas from the water. This can prevent liquid from leaving the pipe along with air.

The pump is placed on a special foundation or concrete floor, where it is leveled using a level, and then secured using anchors in a standard hole. Nearby you need to place a water tank with a volume of 30 liters or more. Several tubes are connected to it. The first is needed to collect water, the second is to drain the waste liquid into the tank.

When circulating, the water will heat up, and this will negatively affect the pump. To ensure natural cooling, the tank is made of a material that conducts heat well. It can be aluminum or steel.

The pipe that supplies water to the pump must be equipped with a special tap that shuts off the water when not in use. The pump and tank are connected using a flexible hose, and everything is secured with metal clamps.

When the pipeline is completely assembled and secured, the installation can be tested. We provide power to the pump according to a temporary circuit using a circuit breaker. But it is still advisable to carry out this at the moment when the electrics are completely installed.

Main varieties

Today, two types of vacuum presses are produced:

• conventional type equipment (such presses are used in cases where it is necessary to exert the most gentle influence on the workpiece, and are capable of creating pressure the value of which does not exceed 0.95 kg/cm 2
  );
• high-pressure vacuum presses (equipment of this type is capable of providing pressure up to 8.5 kg/cm2
  ).

In a conventional press, the facing material is pressed against the part by atmospheric pressure, and in a press with excess pressure, compressed air is additionally pumped into the cavity above the workpiece

Equipment of the first type is used in cases where it is necessary to cover products with a simple configuration with PVC film or veneer. Vacuum presses capable of creating high pressure are used for veneering or covering with PVC film parts of complex shapes. In addition, such equipment is often used as a vacuum molder, with the help of which three-dimensional products of various configurations are made from sheet plastic.

The most common two layout options for vacuum presses are:

How to make a lifting, pressing, top frame

We use a 60x40x2 mm profile pipe as the frame material. The clamping frame is made exactly in the same dimensions as the vacuum frame. If it was not possible to get an even profile - not bent or twisted, then we select the straightest sheets in pairs. From these we will make parts of the vacuum table that fit tightly together.

The lifting of the clamping frame will be carried out through adjustable hinge joints. The hinges can be adjusted when a seal is glued in the form of strips of sheet rubber with medium hardness - approximately 2 mm thick.

Welded washers are required to increase the friction area. The hinge pin is in the form of a steel rod D12, the ends of which have threads.

To keep the pressure frame raised, we can use gas elevators.

Now let's start making the mold

Any materials can be used as a form: wood, plaster, etc.

If high smoothness of the form is not required, then polyurethane foam can be used, since it can be easily processed with a stationery knife.

If there are concave places on the form, then it is necessary to drill a hole in each recess with a thin drill d = 0.1-0.5 mm.

Construction drawing

This version of a homemade vacuum press is supposed to be equipped with a recoil-type thermal module (see diagram below).

Other types of heaters - lifting and swing - are more difficult to manufacture and less convenient to use. The thermal module is equipped with rollers (ball bearings) and moves on rails (20x20 pipe). There is a parking space for it on the frame.

The dimensions chosen for the vacuum chamber are 2.5 x 1.4 m. This length is optimal for the manufacture of the most typical furniture facades, and the width corresponds to the most common type of PVC film.

Vacuum press drawing

It is intended to load parts with a thickness of no more than 32 mm into the chamber, so its height, taking into account the thickness of the linings, air-permeable platform and seals, is taken to be 60 mm (made from a pipe 60x40x2 mm).

Main Types of Vacuum Forming Machine

The operation of a vacuum forming machine is based on the vacuum forming process. It allows you to give the plastic blank the desired shape.

Its essence boils down to the fact that a special plastic blank, which is subjected to high-temperature heating, is placed in an insulated special vacuum chamber above a matrix of the required shape.

Then, under the influence of the pressure difference formed when air is pumped out of the chamber, the workpiece takes the form of a matrix and thus a product of the required shape is formed.

Depending on the size of the parts produced with its help, such machines can be divided into machines for the production of:

• large-sized products, usually used in large-scale production and used on an industrial scale;
• medium-sized – used for medium-series and single-piece production of products on an industrial scale;
• small-sized – used for small-scale and single-piece production of parts.

Vacuum forming machines can also be divided into automatic and semi-automatic. In the latter, the process of feeding and removing the workpiece is carried out manually.

Depending on the technical characteristics and the ability to create a certain pressure and temperature, vacuum forming machines can work with workpieces made of PVC, ABS, PMMA, acrylic and similar materials, which allows it to be used to produce a wide variety of products of any shape and ensuring high quality products .

Preparing the model. First mistake

There should be no negative angles in the model, i.e. all bevels and ends must have angles greater than 90 degrees. The side surfaces must have at least a minimum slope of 2-3 degrees so that the model can be easily removed from the matrix. The matrix must be made higher, because in the corners adjacent to the table, it is impossible to completely remove the air; this will give a smooth bend towards the table. It is better to cut off the lower part. How much higher to go depends on the thickness of the sheet, the power of the equipment and how much you will heat the polymer material.

Do-it-yourself vacuum press: what do you need to know?

Before working on making your own vacuum press, remember the following:

• 5 years after assembly, the device must be upgraded or purchased a new one;
• possible malfunctions are eliminated only within a certain period of time;
• the device has only manual control;
• Available and common materials are used for work;
• do not chase a beautiful design of the structure;
• speed and convenience should be no worse than factory analogues.

If you plan the purchase of components and carry out the work correctly, the cost of a press made by yourself will be significantly lower than its factory counterpart, and you will be able to make film facades and MDF overlays at home.

Press device

Let's look at the design of a vacuum press using the example of the Master Compact model, which is very popular today. It consists of:

1. Heating system. Special lamps are used as heating elements, the type of which differs depending on the scale of production. High-quality heaters provide heating to the required temperature in 2 minutes;
2. Desktop. The design of this element allows for cladding for flat or, conversely, radius elements, the height of which can be 300 mm or more. As a rule, tables are made of high-quality aluminum, the thickness of which is at least 6 mm. The table should provide convenient access to the workpiece from all four sides;
3. Lifting systems. As a rule, this is a spring-lever mechanism of the thermal module, which is capable of compensating for the weight of the so-called heating cap itself. In this case, when unloading and loading workpieces, the operator does not need to spend a lot of effort;
4. Thermomodule. This is a closed device that must protect the workpiece from any environmental influences and changes in temperature or pressure level. Otherwise, it may affect the quality of the future product. Often thermal modules are equipped with viewing windows, allowing the operator to control the entire process of applying film to a wooden workpiece;
5. Vacuum pump. The Master Compact press is equipped with a German Busch pump, which has a capacity of 40 m3/h. However, the system can also use other vacuum pumps, each of which differs in its operating principle and characteristics of the pressure created inside the working chamber;
6. Control systems. It is a control panel that can switch to manual or automatic mode. For example, the Master Compact system uses a three-phase inverter power controller, which allows you to smoothly change heating rates. This is a very useful option, as it ensures that the object is not deformed due to heating of the film at different intensities. The control system is also responsible for monitoring the heating element in case it fails or begins to malfunction;
7. Membranes. Most often used when processing so-called breathable materials. It presses the film and allows you to cover even complex, bent furniture elements with film;
8. Pin systems. Thanks to the presence of such a module, there is no need to prepare supports for the workpiece. This significantly speeds up the work process and simplifies the operator’s task. However, such systems are not installed in all vacuum presses, so before purchasing you need to check the availability of this module or order it additionally if the design involves integration;
9. Mobile stand. It is very convenient for rolls of film material. In the Master Compact model, such a rack allows you to install 6 rolls at once, after which the press automatically begins to use them one by one. This also speeds up and simplifies the processing process;
10. Knife. Typically, presses are equipped with specialized knives for removing excess film after processing;

Vacuum pressing

Vacuum pressing is a process by which curved glued furniture and interior elements are created and coated. Today there are a huge variety of installations with different capabilities. There are universal installations that can work with film or natural material.

During the pressing process, various tables can be used to perform their functions. If necessary, they are equipped with thermal elements that enhance the pressing effect. Installations differ in the level of automation. At enterprises with conveyor production, fully automated vacuum presses are used.

Vacuum pressing may differ:

• on the design of heating elements;
• method of moving heating elements;
• type of fastening of the removable membrane;
• type of heating module;
• applied vacuum pumps;

Thermal vacuum press is one of the most common units in vacuum pressing. He copes with cladding furniture facades with PVR film, doors with veneer material, as well as manufacturing bent-laminated products that have dimensions that do not exceed the dimensions of the press.

A system that includes a vacuum bag is often used. This is due to the strong different properties of materials, which can be natural and artificial. In addition, different temperatures can be used when working with PVC film. The operation is especially important when performing 3D pressing, when it is necessary to ensure the elasticity of the film.

Vacuum molding of plastic

Vacuum plastic forming is a process that produces products and thermoplastics. These are acrylic, polyesterol, PVC and other polymers. To change their shape, vacuum is used, as well as high temperature. Vacuum forming, as a rule, is a mass production of products. At the same time, there are small installations with which you can create small souvenirs or other similar products.

Vacuum molding of plastic is actively used:

• when creating outdoor advertising elements: logos, three-dimensional letters and other elements;
• in the manufacture of equipment for trade: front and side panels, shelves, trays, baths, covers and other elements.
• when creating car elements: moldings, plastic panel parts, tool boxes and many other products;
• when creating household products: aquarium lids, trash containers;
• when creating interior elements: figurines, furniture elements;
• when creating components of medical installations: consoles, containers, baths;

Items made by vacuum molding are present in large quantities in the life of every person. This technique is one of the largest today and is used in almost all industries.

Clamps

To hold the film securely and airtight when vacuum pressing occurs, we press the top frame tightly and evenly against the perimeter of the vacuum frame. This way the rubber seal will fit completely.

Homemade clamps, which operate on the eccentric principle, are made from the following rolled steel:

• 1 pipe DN50: 0.5 m, with an outer diameter of approximately 60 mm; • rod: 2 m, diameter 10 mm; • profile pipe: 2 m, 20x20x2 mm.

We adjust the clamps by installing combination nuts in the desired location on the stud thread and securing them with locknuts. This operation is performed at the final stage of manufacturing the vacuum table, after the rubber seal has been glued.

Learn how to create several tons of pressure per square meter when gluing veneer.

Working with veneer is much easier than you think if you use a vacuum press to compress the glue. To introduce our readers to this process, we turned to professional furniture maker Matt Sailer, who often uses veneer in his work.

According to Matt, veneer offers several advantages.

“It allows you to change the direction of the grain pattern on the facing surfaces and even mix different species, which is difficult and sometimes impossible to do with solid wood. Companies that produce and sell veneer offer products from hundreds of wood species and a huge variety of patterns and shades. This palette is simply amazing.”

WHAT IS NEEDED FOR VACUUM PRESSING

How does this system work?

The vacuum bag evenly distributes significant pressure over a large area, even over concave and convex surfaces, which is difficult and sometimes impossible to achieve with conventional methods. When air is pumped out of a sealed bag, the pressure from outside air compresses the bag and its contents. If you think that such a clamp will be too weak, keep in mind the following: a panel measuring 610x915 mm inside the bag is compressed with a force of about 5.5 tons (if the process occurs at sea level. With increasing altitude, atmospheric pressure decreases, and at an altitude of 1500 m above sea level the force will be 4.8 t).

The photo below shows the main elements of the vacuum system. A basic set of pump, hose with fittings and vinyl bag measuring 125x125 cm can be purchased for S400. To veneer long panels (such as in the Sixties Cabinet project), you need a bag measuring 125x250 cm. A vinyl bag of this size costs about $75, and a more durable polyurethane bag will cost $215. Although the vacuum bag creates a fair amount of pressure, unadhered areas and swellings (so-called “siskins”) may be found on the veneer if additional measures are not taken. Matt makes a "sandwich" by sandwiching the veneer panel between two pressure plates to distribute the pressure more evenly.

Read also: How to put a measuring tape back together

Make these plates from 19mm MDF board or laminated chipboard. Their dimensions should be approximately 25 mm larger than the package of parts. Mill 6mm fillets on all edges and corners to avoid damaging the vacuum bag. On one of the plates, use a saw blade to make a grid of 3 mm cuts with a pitch of about 100 mm. This will help completely pump the air out of the bag.

Do not use contact glue. Contact adhesive is considered the best choice for gluing sheets of plastic, but Matt recommends avoiding it if you're gluing wood to wood: "Under veneer, contact adhesive dries out, causing edges and corners to pull away from the backing and become easily damaged."

Choice of base and glue

For strong bonding, veneer requires a smooth surface called a base or substrate. MDF board is excellent for use as a base for panels such as doors, false panels and countertops. For the panels on which the joints are then made, choose maple, beech or birch plywood. “But oak plywood should not be used,” says Matt, “its large pores will show through the thin veneer after pressing.” Since you will be sawing the panels to final dimensions after gluing the veneer, make the base, including the edge caps, approximately 12 mm larger in width and length. The glued overlays must be at least 25 mm wide so that after filing there is enough material left for routing the profiles along the edges.

If you want to cover a panel smaller than 60x60cm with one piece of veneer, you can use regular yellow PVA glue. For larger areas, or if the shirt is assembled from several pieces of veneer, Matt uses a special one-component cold-press adhesive. “It lasts longer so you can work without fuss, and the increased viscosity reduces glue bleed through seams.” Some manufacturers offer light, medium and dark varieties of this glue, and this helps make the glue lines less noticeable.

How to cut veneer

To cut veneer, Matt uses three simple tools: a sharp knife with a retractable blade (for cross cuts), a so-called plywood saw (for rip cuts), and a steel ruler to guide them (photos A and B). Quick tip! Place a strip of 150-grit sandpaper on the underside of the ruler to keep it in place as you work. Place the veneer sheet on a piece of MDF board to avoid leaving scratches on the workbench cover when cutting. Press the ruler against the veneer as tightly as possible to prevent movement. For best results, do not try to cut the veneer in one motion, but make several long, light cuts along the edge of the ruler.

When cutting veneer across the grain, make cuts from both edges to the middle to avoid splitting the edges. Change blades frequently to keep them razor sharp.

For longitudinal cutting in a straight line, use a plywood saw instead of a knife (the blade of the knife often deviates from the ruler in the direction of the grain). Move the tool towards you and make a few light cuts to cut right through the veneer.

If the panel is large, to cover it you have to glue together several pieces of veneer (“pick up a shirt”). To do this, lay the veneer strips face down on a workbench, align and join the cut edges. Make sure that the texture pattern at the junction of the stripes looks the way you want. Then place pieces of masking tape across the joint to temporarily hold the veneer strips together (Photo C).

Turn the shirt over and place a long strip of tape along the seam line on the front side (photo D ).

Apply short strips of masking tape across the joint at intervals of about 10cm to ensure the veneer sheets fit together as tightly as possible.

With the sheets together on the back side, apply a long strip of tape along the seam to the front side (which will be visible on the finished panel).

This will prevent excess glue from squeezing out onto the front side through the seam, and you will spend less time removing it after you remove the panel from the vacuum bag. Turn the veneer over again and remove the short pieces of tape. Quick tip! The strips of tape should not overlap each other, and there should be no wrinkles or folds on them, so that during pressing, dents do not appear on the veneer.

Don't forget the other side

Because the adhesive dries first at the edges of the panel and then in the middle, the difference between the dry edges and the wet middle creates stresses that can arch even a 19mm base. By gluing veneer to both sides of the panel, the stresses will be balanced and the panel will remain flat. Matt says: “The veneer for the back doesn't have to be anything special, and you can use any inexpensive grade of veneer. But it must be glued to the base at the same time as the face veneer, using the same glue.”

Let's start pressing

Orient the veneer shirts as they should be placed on the base. Protect the sides of the pressure plates that will be in contact with the veneer with wax paper, securing its edges with tape. Apply glue to the back of the base (not the veneer!) as shown in Photo E. (If you smear the veneer, it will curl up and be difficult to straighten.) Excess glue from the base can be easily and quickly removed with a putty knife.

To quickly and evenly apply the glue, Matt uses a rubber roller. Having poured the glue from the bottle, he rolls it with a roller over the entire base, leaving no dry spots.

Place veneer on the back side and level it. Its edges may begin to curl into a tube from moisture that is absorbed from the glue. Matt secures these edges with short strips of masking tape. Then flip the panel over, placing it back on the pressure plate, and glue the veneer to the front side. Place a pressure plate with cuts on top of the panel and place the entire “sandwich” in a vacuum bag (photo F ). After straightening out all the folds on the bag, fold the edge, put on the clasp and turn on the pump. “I haven’t seen a bag that’s completely sealed yet,” says Matt, “so keep an eye on the pressure and don’t turn off the pump until the glue dries.” After about an hour, turn off the pump and remove the contents from the bag. Carefully remove the masking tape so that it does not stick to the veneer due to the excess adhesive squeezed out (photo G). Place the panel and pressure plates back into the bag, turn on the pump and leave the glue under pressure for another three hours.

Read also: How to check the battery of a screwdriver with a multimeter

Place the pressure plates with the panel and veneer in a bag. To effectively remove air, the fitting with the valve must be located at the intersection of two cuts (photo insert).

The glue has barely set, so be careful not to pull the veneer away from the base. Pull the tape away from the joint to avoid tearing out individual fibers.

Processing the panel after the press

When the glue has dried, trim one edge with a sharp chisel or knife (photo H). Then saw the panel to final dimensions (Photo I).

Lightly cut away the exposed veneer on both sides of the panel to create a smooth edge to fit the rip fence of the machine.

To reduce chipping on the ends and edges of the panel, apply masking tape along the cutting line to support the veneer fibers when sawing.

Almost invisible repair

Do not despair if an edge or corner of the veneer breaks off when trimming overhangs or filing a panel. “It happens,” Matt says, “but repairs are a lot easier than you think.”

First of all, from the remaining veneer, select a piece whose color and texture pattern matches the damaged area. The greater the similarity, the less noticeable the patch will be. Cut the patch slightly larger so that the edge is parallel to the grain or at an angle (Photo J ). A joint perpendicular to the grain is difficult to make invisible.

Place the patch on the damaged area and run the corner of a chisel along its edge, cutting into the veneer. Then, starting from the edge of the panel, remove the veneer up to the score line (photo K). Reapply the patch and secure it temporarily with tape. A small piece of tape will allow you to see the joint and make sure the fiber pattern matches. If you are happy with the appearance, lift the patch, apply glue (photo L) and press the patch again (photo M), leaving the clamp in place for at least two hours. After sanding, the repair site will not be easy to locate (photo N).

Cut the patch slightly larger and sand or file a straight edge at an angle to the grain to make the joint less noticeable. Determine the exact position of the patch.

Using a sharp chisel, deepen the cut to completely cut through the glued veneer. Then carefully remove the damaged veneer.

Once the patch has been accurately aligned, place a strip of masking tape across the joint. Lift the patch, apply glue to the backing, then apply the clamp.

A clamp made from a piece of MDF board distributes pressure evenly and the patch does not move. The wax paper will prevent the trim from sticking to the veneer.

Thanks to the careful selection of the grain pattern and the perfect line of junction of both parts, the patch is difficult to detect.

The vacuum press is a unit that allows you to produce various furniture facades with PVC film based on MDF, as well as decorative door trims. You can buy it in a specialized store or make it yourself at home. It is necessary to remember that if you decide to make such equipment with your own hands, you will need to try very hard, observing all safety rules.

How to make a vacuum table

Vacuum bath

A 2 mm steel sheet is used as the bottom of the vacuum bath. In order to minimize the deflections of the sheet, which will be affected by negative internal pressure, and to make the table surface as even as possible, we proceed to the manufacture of the stiffening frame. We make this design from the same profile pipe 60x40x2.

The pre-cut pipe, as indicated in the project, is laid on the slipway, rigidly secured with clamps, and all connections are welded. When the stiffening frame is ready, a sheet of steel is welded on top of it. At this most critical stage of welding work, a continuous sealed weld must be ensured. It is recommended to do it with double boiling.

To prevent the sheet from warping due to prolonged exposure to high temperature, you can use the following alternative method to weld the sheet to the frame. Before laying the steel sheet on the stiffening frame, we apply a sealing compound around the perimeter of the sheet, which is designed to withstand high temperatures. Here you can use, for example, silicone high-temperature sealant. Welding is not carried out in the form of a continuous seam, here we make regular fixing tacks - a step of approximately 50 mm.

This method ensures that due to short-term local effects of welding, the entire sealant will not be damaged or burned out, but only a small part directly at the tacks. For the most part, the sealant, after it hardens, will perform its function.

How to make a stiffening frame and assemble a vacuum bath:

• welding the stiffening frame; • weld a sheet of steel to it; • around the perimeter of the sheet we hermetically weld a stationary lower frame, which includes a part of the hinge joint that fixes the lifting upper frame.

How to choose the right equipment

When choosing a membrane-vacuum press to solve certain problems, you should focus on its most important parameters.

Pump brand and country of origin

Vacuum presses can be equipped with pumps from foreign (usually Italian) or domestic manufacturers. In the first case, a membrane vacuum press will cost more, but the pump installed on it will be more reliable. Meanwhile, domestic vacuum pumps are also quite reliable, but most importantly, there should be no problems with their repair, since finding spare parts for domestic pumping equipment is not particularly difficult.

The reliability and performance of the press depends primarily on the vacuum pump

Vacuum table lining material

It is very important that it is metal, and not chipboard sheets, which some manufacturers use for such purposes. After a short period of use, tables made from chipboard will simply become unusable.

Dimensions

This is one of the most important characteristics that you should pay special attention to when choosing a membrane vacuum press. The dimensions of the vacuum press primarily determine the number of workpieces that can be processed on it simultaneously. Naturally, the larger this quantity, the more productive the vacuum press will be. Meanwhile, it should also be taken into account that the size of the equipment directly affects its cost, so in this case the best option should be chosen.

Vacuum presses are manufactured in standard sizes, for example, for veneer veneering, the most commonly used sizes are 2500x1500, 3000x1500, 2500x1200 or 3000x1200 mm

Type of heating devices

The vast majority of experts advise choosing vacuum presses equipped with KGT lamps, when using which the film glued to the top of the bent parts does not melt or burn through. In the same case, if you select equipment equipped with heating elements, you will have to constantly monitor that the distance from such heating elements to the very top of the workpiece surface is at least 150 mm.

Press brand

Since vacuum presses are quite expensive equipment, it is not worth choosing a device from unknown manufacturers, which will then have to be constantly repaired.