ADDITIVE MANUFACTURING
temperature final sheet material, higher temperature pellet feedstocks should be used for printing the mould, such as GF- PC or filled nylon material. Another advantage is the ability to
leverage a porous surface of the printed part, allowing a vacuum to pass through a mould without having to use special tools to make the vacuum holes. According to Duo Form, the inherent porous nature of 3D-printed moulds presents a significant advantage when employing pellet-extrusion 3D printing in its mould production process. Depending on the intended final thermoformed part, it may be important to prioritise the flow of vacuum through certain zones of the mould to be able to get the desired outcome of the forming process. Tis goal can be accomplished by adjusting tool pathing parameters before printing.
ADVANCING PRODUCTION WITH PELLET-EXTRUSION AM Duo Form, a US leader in thermoforming for many industries, is making continuous efforts to innovate its processes to reduce lead times and costs, allowing the company to better serve customers and win new business. To integrate this technology into its manufacturing process, Duo Form collaborated with 3D Systems. AM offered the company more agility by 3D printing production moulds, tools, and representative samples for thermoforming and vacuum forming. Te company embarked on a project
involving 3D printing a 1294 x 410 x 287mm train interior panel with the potential of reducing cost by up to 88% as well as lead time by 65%. Te combination of an EXT 1270 Titan Pellet 3D printer and glass-filled polycarbonate pellets led to a major cost
The thermoformed train interior panel
and time reduction. Immediate results were perceived with their subsequent first 3D-printed mould, a shower pan for recreational vehicles. Te outcome was a high-quality AM mould with durability comparable to moulds produced through traditional methods. Over 1,000 shots have been pulled from the mould without notable signs of wear. David Rheinheimer, Duo Form
product development manager, says: “We have gained a lot of business with our Titan 3D printer. Te turnaround time for parts, moulds, and formed parts has put us leaps and bounds above our competition.” Since implementing AM as part of its manufacturing process, Duo Form says it has won more business and now closes deals faster thanks to
the speed and agility of pellet-extrusion 3D printing. In fact, when Duo Form 3D printed a sample part to present to a customer along with a quote for forming the part, the customer, impressed with the speed and ability to see the final design first, awarded the company the bid that same day. Tis has now become standard practice for Duo Form and brings added value to its customers.
REVOLUTIONISING MANUFACTURING AM is reshaping production processes and the way companies perceive them. Large-format pellet extrusion 3D printing is amongst the technologies leading the way. Tis advanced technology will enable industry leaders to benefit from a competitive edge with increased speed, improved cost management, and higher- quality part production. We are only scratching the surface of the possibilities that pellet extrusion can offer in the thermoforming industry and other applications. With the ongoing evolution of innovation, AM will consistently showcase its ability to mould the future of manufacturing.
Composite image showing (clockwise from bottom left) – 3D printed mold, untrimmed thermoformed panel, installed panel in a train
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www.engineerlive.com
Clay Guillory is the Director, Titan at 3D Systems.
www.3dsystems.com
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