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A female mold vacuum forming apparatus and a method for using the female mold vacuum forming apparatus for providing improved draw depth capability. The female mold vacuum forming apparatus comprises a top contoured surface and a cavity having a cavity surface formed within the top contoured surface

A female mold vacuum forming apparatus and a method for using the female mold vacuum forming apparatus for providing improved draw depth capability. The female mold vacuum forming apparatus comprises a top contoured surface and a cavity having a cavity surface formed within the top contoured surface. The cavity surface defines part geometry having deep-draw sections. The top contoured surface defines open sections in the side surfaces of the mold adjacent to at least one deep-draw section to allow free formation of parts within said at least one deep-draw section.

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1. A female mold vacuum forming apparatus comprising:a top contoured surface,a cavity formed within the top contoured surface, said cavity having a cavity surface, said cavity surface containing air canals,said cavity surface defining part geometry and having at least one deep draw section with a de

1. A female mold vacuum forming apparatus comprising:a top contoured surface,a cavity formed within the top contoured surface, said cavity having a cavity surface, said cavity surface containing air canals,said cavity surface defining part geometry and having at least one deep draw section with a depth greater than one half of the longer width of said cavity,said top contoured surface defining open sections in the side surfaces of the mold adjacent to at least one of said deep-draw sections to allow free formation of parts within at least one said deep-draw sections, said open sections define a depth that is at least one third the depth of the adjacent at least one deep-draw section, anda clamp adapted to hold the thermoplastic sheet, said clamp engaging said top contoured surface at areas other than said open sections and, when engaged with said top contoured surface, said open sections being spaced apart from and beneath said clamp. 2. The female mold vacuum forming apparatus of claim 1 wherein the cavity surface is made of a porous material. 3. The female mold vacuum forming apparatus of claim 1 wherein said cavity surface defines more than one of said deep draw sections having a depth greater than the length of half the longer width of the cavity. 4. The female mold vacuum forming apparatus of claim 1 further comprising a plug adapted to engage a thermoplastic sheet around said part geometry, wherein during operation the plug, the female mold and the thermoplastic sheet form a seal around the part geometry. 5. The female mold vacuum forming apparatus of claim 4 wherein said plug includes a bottom surface adapted to substantially register with the part geometry of the female mold. 6. The female vacuum forming apparatus of claim 1 wherein the clamp is configured to be in a substantially horizontal plane. 7. A female mold vacuum forming apparatus comprising:a mold having side walls and a bottom wall defining a cavity and a cavity surface containing air canals, said cavity surface defining part geometry having deep draw sections,wherein at least one open section is defined in a side wall of the mold adjacent to at least one deep draw section to allow unhindered formation of parts within said at least one deep-draw section, said at least on open section defining a non-molding region of said cavity, said at least one open section defines a depth that is at least one third the depth of the adjacent at least on deep-draw section. 8. The female mold vacuum forming apparatus of claim 7 wherein the cavity surface is made of a porous material. 9. The female mold vacuum forming apparatus of claim 7 wherein said at least one deep draw section has a depth greater than the length of half the longer width of the cavity. 10. The female mold vacuum forming apparatus of claim 7 further comprising a plug adapted to engage a thermoplastic sheet around said part geometry, wherein during operation the plug, the female mold and the thermoplastic sheet form a seal around the part geometry. 11. The female mold vacuum forming apparatus of claim 10 wherein said plug includes a bottom surface adapted to substantially register with the part geometry of the female mold. 12. The female vacuum forming apparatus of claim 10 further comprising a clamp for holding the thermoplastic sheet. 13. The female vacuum forming apparatus of claim 12 wherein the clamp is configured to be in a substantially horizontal plane. 14. A vacuum forming apparatus comprising:a female mold having a top contoured surface,a cavity formed within the top contoured surface, said cavity having a cavity surface, said cavity surface containing air canals, said cavity surface defining part geometry having deep draw sections,a plug adapted to engage a thermoplastic sheet around said part geometry, wherein during operation the plug, the female mold and the thermoplastic sheet form a seal around the part geometry,said top contoured surface and said plug, when engaged with the sheet around th e part geometry, define open sections in the side surfaces of the mold adjacent to at least one of said deep-draw sections to allow free formation of parts within at least one of said deep-draw sections.