Abstract
Vacuum forming is utilised extensively in the Industrial Design practice for prototyping as well as the low
volume manufacture of plastic components. In the broader plastic manufacturing sector, the process is
widely utilised for many industries, from a single, one-off product to higher volume production of
packaging, appliance componentry, automotive componentry, agricultural pots and trays and mould
components. Plastic manufacturing contributes substantially to South Africa’s Gross Domestic Product
(GDP). Despite the significant contribution, there are significant challenges facing SMME’s in the
manufacturing sector. Competition from foreign markets, high costs associated with acquiring suitable
machinery, and the impact of an unstable electricity supply on manufacturing are significant contributing
factors. This reflects the broader issues in the manufacturing landscape linked to South Africa's unique
socio-economic conditions, with high unemployment rates, a lack of skills transfer and high levels of
inequality prevalent in the economy. Through outlining the context and challenges facing small-scale
plastic production and prototyping in South Africa, there is little research and solutions in the consideration
of a vacuum-forming machine that meets the challenges of the local small-scale manufacturing market.
The need to adapt prototyping and small-scale manufacturing techniques to align with the South African
product development and small-scale manufacturing environment is vital for the long-term growth and
sustainability of design and manufacturing SMMEs. This study aims to address the gap in the research
and practical implementation of a small-scale vacuum forming machine to empower entrepreneurial
practices through accessible small-scale manufacture of plastic products. To guide the study, the Design
Thinking Model for Innovation, viewed through a Pragmatic paradigm and guided by Research through
Design employed qualitative research techniques and tools. The data gathered supported a Human-
Centred Design process, guided by Appropriate Technology, Frugal Innovation, Design for Manufacture
(Design for Assembly and Design for Disassembly) and Design for Usability. The Industrial Design
product outcome is a small-scale vacuum forming machine suitable for implementation in the South
African context. Supporting the product development process, the use of Digital Manufacturing
techniques, processes and theories were vital to generate prototype components.