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At present, there is a growing tendency among industries to integrate eco-friendly practices to comply with the increasingly stringent environmental standards that are being introduced. In this context, a variety of sustainable machining methods have been investigated with the objective of optimizing processing parameters. The objective of this study is to optimize processing parameters for the manufacturing of plastic sheets using a vacuum-forming process. This method is costeffective and versatile, offering superior surface finishes, reduced manufacturing costs, and increased productivity. It addresses issues that arise from the use of unoptimized parameters, which are typically determined through a process of trial and error or based on the experience of the operator. In this study, the heating temperature, heating time, sheet thickness, and distance between ups were identified as the optimal parameters for optimization. Uniformity and the number of wrinkles were selected as performance assessment attributes. The experiments were conducted in accordance with the Taguchi L16 orthogonal array (OA) experimental design plan. It was determined that the thickness of the sheet and the distance between the ups are significant consequences in determining the quality of vacuum-formed parts. The experiments demonstrated that the sheet type, color, and size of the venting hole in the male mold had a negligible impact on the formation of wrinkles. The results of the ANOVA demonstrated that uniformity and the number of wrinkles were significantly influenced by the sheet thickness and distance between ups. The Taguchi analysis identified the optimal process parameters that enhanced the product quality, as evidenced by the results of the conformance tests. Additionally, regression analysis was utilized to predict outcomes and assess the model. The developed regression models are recommended for implementation in manufacturing industries to optimize parameters, reduce material waste, enhance productivity, and improve cost-effectiveness.