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FEATURE MATERIALS IN DESIGN & PROTOTYPING


TRANSFORMING THERMOFORMING PROCESSES WITH 3D-PRINTED MOULDS


3D printing is enabling manufacturers to produce thermoforming moulds quickly and more cost effectively than traditional methods, as Clay Guillory, director, Titan, 3D Systems, explains


to gain a competitive edge – producing medium-to-large-sized thermoforming moulds in less than half the time, and at a fraction of the cost, compared to traditional mould-making methods. So how exactly can companies leverage Additive Manufacturing (AM) to assist in traditional vacuum and thermoforming processes, making them faster, more cost-efficient, and more agile?


M


SUBTRACTIVE AND ADDITIVE MOULDS In conventional thermoforming, plastic sheet material is shaped over moulds to produce the finished part. Thermoforming often includes vacuum forming, which assists in pulling the plastic sheet over the mould. Such moulds can be produced in a variety of ways – using ceramics and CNC machining of metals, wood, tooling board, or hand- sculpting of wood. These subtractive processes selectively remove material from a block with a cutting tool to create the desired shape for a pattern or a mould. Additive processes build parts layer-by-layer


by extruding material such as a thermoplastic to create just the shape that is needed, such as a pattern or mould. AM production offers efficient, cost-effective mould production compared to traditional methods, leading to shorter lead times and increased production flexibility.


REAL-WORLD BENEFITS OF EXTRUSION PRINTING But which 3D printing technique is the best for mould making? For medium-to-large-scale items, up to a size of around 1 x 1.8m, printing with plastic pellets works best thanks to its low cost and high extrusion throughput. Thermoplastic pellets, which can be up to ten


times less expensive than traditional 3D printing filament, are regarded as the most affordable feedstock for AM. The ability to print moulds up to 1270 x 1270 x 1820mm utilising high- performance, high-temperature, materials at


anufacturers are discovering how to leverage large-format extrusion 3D printing using low-cost plastic pellets


Duo Form, a Michigan-based thermoforming leader, uses pellet extrusion 3D printing to improve production processes


moulds compared to traditionally manufactured moulds out of ceramic, metal or wood. The surface finish of 3D-printed moulds can


be addressed based on the final specs of the formed part. If the ‘B’ side of the final part is the surface that contacts the mould, often no post-processing of the AM mould is required. If a smoother surface finish of the mould is required, manufacturers can select smaller nozzles and layer height settings to achieve higher resolution printing or can quickly machine the surface of the 3D printed mould either during or after printing to achieve a smooth finish.


speeds up to a half metre per second delivers improved efficiencies and reduced cost. Maintaining mould quality is key and several


materials have been validated for AM moulds. Glass-filled polycarbonate, carbon-fibre-filled ABS (CF-ABS), and nylon pellets, are reliable materials for such applications. When selecting a pellet feedstock, thermoformers should consider the final sheet gauge, temperature requirements and accessibility. Lower-temperature materials like CF-ABS are suitable for thinner gauge sheets, while higher-temperature feedstocks like GF-PC or filled nylon are suitable for thicker gauge or higher-temperature end sheet applications. Due to the inherent porosity of extrusion 3D-printed parts, this technology is ideal for allowing a vacuum to pass through the mould without the need to use special equipment to create vacuum holes in the mould. The result: thermoforming companies report better and deeper pulls from pellet-extrusion 3D printed


58 DESIGN SOLUTIONS JULY/AUGUST 2023


GROWING PRODUCTION WITH PELLET-EXTRUSION AM Duo Form, a Michigan-based thermoforming leader, uses pellet extrusion 3D printing to improve production processes, shorten lead times and reduce costs, while maintaining mould durability and quality. In one project to create a large train interior panel (1294 x 410 x 287 mm), Duo Form estimated up to an 88% cost reduction and a 65% lead time reduction to 3D print the mould with pellet extrusion compared to conventional ceramic mould processes and significantly larger savings than aluminium mould techniques. By working with 3D Systems to 3D print


production moulds, tools and representative samples for thermoforming on the EXT 1270 Titan Pellet 3D printer, Duo Form was able to become nimbler in its manufacturing process with faster design iterations and ultimately mould production. Duo Form saw quick success with its first 3D-printed mould, a shower pan for recreational vehicles. The mould was high quality and had a similar lifespan to conventional- method moulds with more than a thousand shots pulled on the mould with little to no wear. Duo Form’s product development manager, David Rheinheimer, highlights the company’s success with its Titan 3D printer, resulting in faster turnaround times for parts, moulds, and formed parts. Its implementation of AM has led to increased business and faster deal closures, as it adds significant value to customers.


3D Systems www.3dsystems.com


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