Articulating vacuum plate system and related method

A method of forming a three dimensional article comprising:

• providing a first vacuum plate and a second vacuum plate that cooperatively form a vacuum surface that is at least one of a two dimensional surface and a three dimensional surface, each vacuum plate including a plurality of vacuum ports;
• loading a film on the first and second vacuum plates in a first mode so that the film is adjacent the two dimensional surface and so that the film in of a form that is at least one of a planar, two dimensional form and a first three dimensional form;
• applying a vacuum through the plurality of vacuum ports to draw the sheet toward the vacuum surface;
• and
• articulating at least one of the first and second vacuum plates relative to the other so that the plates cooperatively transition to a second mode, in which the film transitions from the form of the at least one of a planar, two dimensional form and a first three dimensional form, to at least one of a three dimensional form and a second three dimensional form, respectively, while the vacuum continues to be applied via the plurality of vacuum ports of the respective first and second vacuum plates,
• whereby the film takes on the at least one of a three dimensional form and a second three dimensional form to produce the three dimensional article.

An apparatus for forming a three dimensional article from a sheet of film, the apparatus comprising:

• a first vacuum plate;
• a second vacuum plate joined with the first vacuum plate so that the first vacuum plate and the second vacuum plate are configurable in a first mode in which the first vacuum plate and the second vacuum plate cooperatively form a vacuum surface configured to apply a negative air pressure;
• and
• a contoured mold having a three dimensional net shape disposed adjacent the first and second vacuum plates and adapted to selectively receive at least a portion of the first vacuum plate while a film is held against the vacuum surface;
• wherein each of the first and second vacuum plates includes a plurality of vacuum ports and an internal vacuum chamber,
• wherein each vacuum chamber of each of the first and second vacuum plates is separate and independent from the other vacuum chamber,
• wherein each of the first and second vacuum plates is in fluid communication with a vacuum source;
• wherein the first and second vacuum plates in the first mode are adapted to support the film adjacent the vacuum surface and so that the film is in at least one of a generally planar, two dimensional form and a first three dimensional form;
• wherein the first and second vacuum plates are each configurable in a second mode in which the film transitions from the at least one of a generally planar, two dimensional form and a first three dimensional form, to respectively, at least one of a three dimensional form and a second three dimensional form,
• wherein the first and second vacuum plates are configured to not apply a positive air pressure to the film while configured in the second mode.