Vacuum forming is a manufacturing process used to shape plastic sheets into custom designs, such as the shell of a luggage case. The plastic sheet is heated until pliable, then draped over a mold and vacuum-sealed to take the shape of the mold.

Common materials used include ABS (Acrylonitrile Butadiene Styrene), polycarbonate, and polypropylene. These materials are chosen for their durability, impact resistance, and lightweight properties.

Vacuum forming is generally more cost-effective for smaller production runs and offers quicker turnaround times for prototypes and custom designs. Injection molding, while more expensive initially due to tooling costs, is beneficial for large-scale production due to its efficiency and precision.

Advantages include lower manufacturing costs for small to medium production runs, faster prototyping, the ability to create complex shapes with fine details, and reduced material wastage compared to other molding methods.