Design Manual
| Requirement | 1. Vacuum Formed ABS (Plastic) | 2. Pressed Mild Steel (Sheet Metal) |
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| Material thickness | ~2 mm | Typically 0.8–1.5 mm (depending on design) |
| Part size | ~150 x 75 mm | ~150 x 75 mm |
| Forming type | Thermoforming (Vacuum forming) | Cold sheet metal stamping / pressing |
| Parting line / mold type | Female or male mold (positive preferred) | Two-part steel die set |
| Draft angle | Min. 3–5° (ideally 7° for clean release) | 1–3° (depending on press direction and tooling) |
| Minimum internal radius | 1.0 × material thickness = ~2 mm | 1.5–2.5 × thickness = ~1.5–3 mm |
| Minimum external radius | 1.5 × material thickness = ~3 mm | 2 × thickness or more = ~2–4 mm |
| Wall height to base ratio | Max. ~2:1 (higher causes thinning) | Up to 3:1 possible, depending on material and tooling |
| Undercuts | Not allowed (unless with collapsible mold) | Not allowed (unless with complex tooling or extra ops) |
| Surface detail | Medium-to-low (fine textures may blur) | High (can hold sharper details) |
| Tolerances | ±0.3–0.5 mm typical | ±0.1–0.2 mm achievable |
| Fastening features | Must be added post-process (glued/screwed) | Can integrate tabs, holes, flanges into pressing |
| Painting prep | Light sanding + primer before automotive paint | Surface prep + primer; metal may need anti-corrosion |
| Tooling cost | Low to moderate (aluminum or epoxy molds) | High (hardened steel dies + press setup) |
| Production volume | Ideal for low-to-medium volumes | Ideal for medium-to-high volumes |