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Vacuum Forming for Outdoor Applications: UV Resistance and Durability


The manufacturing industry continues to embrace vacuum forming as an efficient and versatile technique for creating plastic parts. This is especially pertinent for outdoor applications where durability and resistance to environmental stressors like ultraviolet (UV) rays are of paramount importance. This blog will discuss how vacuum forming can meet the challenging specifications of outdoor applications, exploring factors such as material choices, process considerations, and practical applications.

The Importance of UV Resistance and Durability in Outdoor Applications

UV Resistance

Exposure to ultraviolet (UV) rays can lead to the degradation of plastics, affecting their color, structural stability, and overall aesthetic appeal. This makes UV resistance a critical factor when considering materials for outdoor elements like signs, playground fixtures, or vehicle components.


Durability is another key concern for outdoor applications that are subjected to various environmental conditions such as precipitation, wind, and temperature fluctuations. Vacuum-formed parts should be capable of enduring these stressors without cracking, deforming, or wearing down.

Material Selection for UV Resistance and Durability

The correct material selection is crucial when vacuum forming items designed for outdoor use.


Polycarbonate is renowned for its impact resistance and can be manufactured in UV-stabilized versions suitable for outdoor use.

High-Density Polyethylene (HDPE)

HDPE offers strong durability and chemical resistance. UV-stabilized HDPE is available for outdoor applications requiring increased sunlight resistance.


This material naturally possesses UV-resistant characteristics and retains its color and transparency when exposed to sunlight for extended periods.


ABS is another material that can be engineered for enhanced UV resistance, and it boasts impressive impact resistance, making it ideal for outdoor use.


ASA is specifically designed for outdoor applications due to its exceptional UV resistance and high impact strength. It maintains its color and mechanical properties even after long-term exposure to weather and UV light.

Material Properties and Behaviors in Depth


ASA is an excellent choice for outdoor applications, not just for its UV resistance but also for its excellent weatherability. It’s able to withstand adverse conditions like high levels of humidity, temperature extremes, and chemical exposures. ASA parts can be color-matched to specific requirements and are less prone to yellowing over time.


When compared to ASA, polycarbonate offers superior impact resistance but may require additional coatings for UV protection. Polycarbonate is often used in applications that require a high degree of visibility as it also offers excellent optical properties.


This material offers excellent resistance against water absorption and is often used in damp or aquatic environments. However, it may lack the structural rigidity of polycarbonate and ASA and might be more suitable for applications that do not require high mechanical strength.


While inherently UV-resistant, acrylic is less impact-resistant compared to ASA and polycarbonate. However, it offers excellent optical clarity and is often used in applications that require transparent parts, such as outdoor displays or windows.


Although ABS is not inherently UV-resistant, UV-resistant grades are available. ABS offers a balance between impact resistance and rigidity but may be less suited for extremely harsh outdoor conditions unless treated with special coatings.

Process Adjustments for Enhancing Durability

Wall Thickness

Increasing the wall thickness boosts the rigidity and durability of the vacuum-formed part, enabling it to better withstand environmental stressors.


Incorporating textural elements into the mold can improve scratch and wear resistance, further enhancing the part’s durability.


Additional post-processing steps, such as the application of UV-resistant coatings or sealants, can augment both UV resistance and durability.

Advanced Processing Techniques

Thermoforming vs. Pressure Forming

Pressure forming is an advanced technique that can be more suitable for parts requiring intricate details or severe draw ratios. This process uses additional pressure to push the plastic into the mold, allowing for better feature definition, which can be critical for functional aspects of outdoor applications.

Twin-Sheet Forming

This process involves forming two sheets of plastic simultaneously, then joining them together. This allows for hollow parts with high structural integrity, making them ideal for outdoor applications requiring lightweight yet robust components.

Case Studies

Case Study 1: Outdoor Signage

Material: UV-Stabilized ASA

Process Adjustments: Increased wall thickness and UV-resistant coatings

Result: Outdoor signage that has remained vibrant and intact for several years.

Case Study 2: Playground Equipment

Material: UV-Stabilized HDPE

Process Adjustments: Mold texturing for improved wear resistance

Result: Resilient playground structures that have stood the test of time.

Case Study 3: Automotive Exteriors

Material: UV-Resistant ABS

Process Adjustments: Optimized wall thickness for impact resistance

Result: Automotive exterior parts demonstrating minimal wear after prolonged outdoor exposure.

Case Study 4: Marine Equipment

Material: UV-Stabilized ASA

Process Adjustments: Twin-sheet forming for lightweight yet robust parts

Result: High-quality marine components that are both durable and UV-resistant, providing long-lasting performance in harsh oceanic conditions.

Case Study 5: Outdoor Furniture

Material: UV-Stabilized HDPE

Process Adjustments: Texturing for enhanced durability

Result: Outdoor furniture sets that have not only withstood years of direct sunlight but also resisted the wear and tear from usage and varying weather conditions.

Regulatory Considerations

Outdoor products often have to meet specific regulatory standards, especially if they are used in public spaces or critical applications like transportation. This may include fire resistance, structural integrity tests, and environmental impact assessments. Vacuum forming materials like ASA and polycarbonate often come in fire-resistant grades that meet these stringent standards.

Future Trends

Emerging materials and technological advancements promise even better UV resistance and durability for vacuum-formed parts. Sustainable materials and coatings are also becoming increasingly prevalent, offering eco-friendly alternatives for outdoor applications.


Vacuum forming is an ideal manufacturing process for crafting durable and UV-resistant parts suitable for outdoor applications. Through thoughtful material selection, including the incorporation of specialized materials like ASA, and specific process adjustments, manufacturers can excel in creating products that go beyond the typical durability and UV resistance requirements for outdoor use. Future advancements in materials and vacuum forming technology are expected to further expand these capabilities.The role of vacuum forming in creating outdoor applications that are both durable and UV-resistant cannot be overstated. It offers a multitude of material options, each with its unique set of advantages and disadvantages. Manufacturers can further tailor these materials through process adjustments and post-processing treatments to meet or exceed the requirements for outdoor durability and UV resistance. As technology advances, we can anticipate even greater capabilities from vacuum-formed parts, expanding their suitability for a wider range of challenging outdoor applications.

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