The A5 thermoformer is a compact vacuum machine specifically designed to work with Worbla and HIPS, allowing you to obtain thermoformed parts with precision and repeatability without the need for large installations. Developed by Simbiox and exclusively distributed by Feroca, its DIN A5 format makes it an ideal tool for small-batch production in workshops, studios, or cosplay and special effects production.
Technical specifications
Feature
Detail
Base size
DIN A5
Compatible materials
All types of Worbla, HIPS (high-impact polystyrene) up to 1.5 mm thickness
NON-compatible materials
PVC, polypropylene, PET
Required vacuum source
Standard domestic or workshop vacuum cleaner (not included)
Assembly
Approximately 5 minutes, hardware included
Designed by
Simbiox (exclusive distribution by Feroca in Spain)
What it is used for
This thermoformer is aimed at users who need to reproduce small parts efficiently, with clean finishes and a minimal learning curve. It is especially useful when working with Worbla Black Art or Worbla Deco Art, and is essential with transparent Worbla — a more demanding material to work with using a heat gun — which delivers exceptional results when vacuum formed.
Series production of small parts for cosplay (shoulder pads, plates, armour details)
Forming Worbla Pearly Art parts with a uniform finish and no tool marks
Thermoforming HIPS up to 1.5 mm for masks, shells and lightweight protective pieces
Duplication of positives and complex geometric shapes from rigid moulds
Production of props, set dressing and theatre or film props in thermoplastic materials
Rapid prototyping of flat or gently relieved parts
How to use it
Assemble the thermoformer following the included instructions. The process takes about 5 minutes using the provided hardware.
Connect the vacuum outlet nozzle to the suction hose of your standard vacuum cleaner.
Place the positive mould on the base grid. Make sure the part does not block the perimeter vacuum channels.
Heat the Worbla or HIPS sheet with an external heat source (heat gun or oven) until it is soft and pliable. The activation temperature for Worbla types is typically between 80 and 100 °C depending on the type.
Place the hot, flexible sheet centred over the mould and the thermoformer base.
Seal the perimeter of the sheet with the clamping frame or bar so that no air enters through the edges.
Switch on the vacuum cleaner immediately. The vacuum generated will conform the sheet to the mould contour within a few seconds.
Keep the vacuum cleaner running until the material has cooled and hardened completely (30–60 seconds depending on thickness).
Switch off the vacuum cleaner, remove the frame and extract the formed part from the mould.
Trim any excess material with scissors or a craft knife and apply the desired final finish.
Usage tips
Choose the right heating temperature
Each type of Worbla has its own optimal working window. Worbla Finest Art is more forgiving, but transparent Worbla requires a more precise and uniform temperature to flow correctly without creating bubbles. Heat the sheet evenly, avoiding cold spots that will not form properly, and act quickly once the heat source is removed.
Moulds and relief details
Rigid moulds with pronounced vertical walls or deep undercuts can make demoulding difficult. Design positives with a minimum draft angle of 3–5° on the walls. For moulds with a lot of fine detail, 1 mm HIPS gives excellent definition, but remember not to exceed the maximum thickness of 1.5 mm or use incompatible materials such as PVC or PET, which could damage the machine.
Grid maintenance and care
After each session, remove any thermoplastic material residue that may have adhered to the grid or frame before it cools completely, as it becomes harder to remove once cold. Periodically check that the vacuum channels are not blocked to maintain forming efficiency. If you use a roller to press the material against the mould before applying the vacuum in tricky areas, you will achieve better definition in the deepest details.
Frequently asked questions
What vacuum cleaner do I need for it to work?
Any standard domestic or workshop vacuum cleaner with a conventional hose nozzle is sufficient. You do not need an industrial or high-powered unit. The A5 thermoformer is sized to work with the airflow produced by ordinary vacuum cleaners. Airflow matters more than power: make sure the connection between the hose and the machine nozzle is well sealed to avoid losing vacuum.
Can I use it with any type of thermoplastic?
The A5 thermoformer is optimised for all types of Worbla (Finest Art, Black Art, Pearly Art, Deco Art) and for HIPS up to 1.5 mm thickness. It is not suitable for PVC, polypropylene or PET, as these materials require different forming temperatures or conditions and could damage the machine or produce unsatisfactory results.
What type of moulds work best?
It works with rigid positive moulds made from any material that can withstand the heat of the activated thermoplastic (plaster, resin, wood, high-temperature 3D prints, etc.). Best results are achieved with shapes that have no pronounced undercuts or fully vertical walls. To make demoulding easier, apply a slight draft angle to the walls of the positive.
How long does it take to form a part?
The actual forming happens within seconds of switching on the vacuum cleaner. The total cycle time depends mainly on how long the material takes to cool: between 30 and 60 seconds for thin sheets of Worbla or 1 mm HIPS, and slightly longer for thicknesses approaching the 1.5 mm maximum. You can speed up cooling by blowing cold air with a small fan or simply blowing on the part.
Can I run repeated pulls from the same mould?
Yes, that is one of the great advantages of this system. Once you have the mould prepared and the process dialled in (heating temperature, vacuum time), you can reproduce the same part as many times as you need with great consistency. The A5 thermoformer is designed precisely for this kind of small-batch production.
Is it difficult to assemble?
Not at all. Assembly is designed so that anyone can complete it in approximately 5 minutes. The machine includes all the necessary hardware and assembly instructions. No special tools are required.
What is the maximum sheet thickness I can form?
For HIPS, the maximum recommended thickness is 1.5 mm. Worbla sheets are thinner by nature and fit perfectly within that range. Exceeding the maximum thickness with HIPS may result in incomplete forming or the vacuum being insufficient to conform the material faithfully to the mould.
Can I use it to make full masks?
The DIN A5 base is suitable for small to medium-sized parts. A full face mask may be tight or exceed the machine's usable area. However, it is perfect for partial mask elements, decorative details, armour pieces and components that are later assembled into a larger piece.
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