This document discusses how 3D printing can be used for thermoforming tooling, specifically prototype and low-volume applications. It provides examples of tooling parts that can be 3D printed like form blocks and plug assists. The document compares the costs of different tooling methods, noting that 3D printed tools can provide savings over wood or aluminum cast tools. It also outlines considerations for designing 3D printed thermoforming tools, such as adding draft angles and vacuuming lines. The document recommends 3D printing technologies like FDM and PolyJet for thermoforming tools due to advantages like quick production and ability to produce complex geometries.

1. Prototype and Low Volume
Thermoforming Tooling
Where 3D printing fits in

2. Barbara Arnold-Feret • Manufacturing manager/GM in plastics and
production facilities, product manager, AE
• Graduate of the University of Missouri – KC
• Pi Sigma Alpha Honor Society
• Society of Plastics Engineers
- 2x Chair of the PD3 Division
- Int’l Executive Board of Directors 2005-2009
- Honored Service Member
- President’s Cup
- Mold Designer of the Year 2012
- Various other awards
• Society of Manufacturing Engineers
- Past Chair of Plastics, Composites and
Coatings Technical Group
- Past New Technology committee
- Various other committees
• Over 42 papers and articles
Barbara Arnold-Feret
Over 30 years in
manufacturing in both
metals and plastics

3. Over 17 years
in business!

4. Thermoforming

5. 5
Thermoforming
Source:http://www.creativeformplastics.com/Thermoforming.html

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Where Can Stratasys help
• Form Blocks
• Plug assist
• Trim Tools

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Other Thermoforming Tooling examples
Any many
other
tooling/molds
for
thermoforming.

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Processing Parts
• Create a dense tool
─ Multiple contours
• Improve surface finish
─ Smaller raster’s
─ Negative air gap

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Processing Parts
• Create a Sparse tool
• Improve surface finish
─ Smaller raster’s
─ Negative air gap

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Cost comparison
Method Cost Time
Wood $1000 7 days
Alum cast tools $7000 14 days
Fiber Layup $580 4 days
FDM $380 2 days
SAVINGS
$200 (34% on lowest
cost method)
50% (on shortest
alternative method)

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Materials used
• ABS-M30
─ 3,000 PSI
• PC
─ 6,000 PSI
• Ultem
─ 10,000 PSI

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PolyJet for Thermoforming Tooling
• require little to no post processing
• well suited for molds with organic and curvy surfaces.
• air channels can easily be designed into critical areas of the mold prior
to printing, eliminating the labor and potential inconsistency of manual
drilling.
• dABS material holds up well to the rigors of molding.
• small parts easily used with thin guage and table forming machines.
• Recommended for intricate parts done in thin sheet or for when optical
clarity is needed.
• Occasional air cooling with shop air is suggested.
• Upper surfaces should be built with gloss surface when possible.

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Sparse style

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Design considerations
• Best practice is to use a minimum draft angle of 1°-3° and a draft angle
of 5° or more.
• Undercuts can be successfully vacuum formed depending on your part
geometry and material thickness.
• Webbing can be mimimized by use of more draft.
• Shrinkage rates depend on material and thickness, but usually range
between 0.4% and 0.8%. You can scale for shrink in the mold design.
• Avoid sharp corners Radius at least the thickness of the sheet.
• Design vac assist lines to pull in female molds and in critical areas and
recesses of male molds. Smaller diameter holes will be less noticeable
on the surface of the formed parts.
• FDM molds may need to be sanded to smooth the surface if the surface
is solid build. Start with 120 grit sand paper and use successively finer
grits as sanding progresses..

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3D printed molds for Thermoforming
• Shorter life compared to metal tooling.
• Faster production, easier to do different designs,
• digital inventory.
• Custom vac assist lines and porosity
• Customer surfaces
• Size may mean segmenting tooling and then joining together
• Best suited for complex and custom shapes
• Use standard backing boards to save costs
• Lower heat transfer ratios may mean that extended cooling time is
needed between cycles.
• CAD is required prior to tool production.

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Industries

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Questions?
866-499-7500
marketing@engatech.com