THERMOFORMING DESIGN
Thermoforming is an affordable manufacturing process where a plastic sheet is heated to a pliable forming temperature, placed in a mold and formed to a specific shape, then trimmed to create a usable product. These parts are durable and relatively quick to produce.
There are design limitations with thermoforming which cannot achieve the fine detail of machining or 3D printing, however, thermoforming offers a lower cost per part than 3D printing.
Because of these design restrictions, it is essential to follow certain guidelines when creating thermoformed parts. Doing so will help create more accurate and durable parts in addition to prolonging the life of the molds for each part.
INTERESTED IN THERMOFORMING FOR YOUR NEXT PROJECT?
TYPES OF MOLDS
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The overall best tooling option for parts smaller than 15”x11”
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The cheapest print option
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High accuracy
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Good for 1000’s of parts
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Generally does not require additional finishing for opaque plastics
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Create long-lasting tooling or multiples of a tool at a lower price than printing
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Requires a 3D printed or machined master mold
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Near-permanent tooling
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Cheaper to reproduce in multiples than 3D printing
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Most cost-effective option for medium to large tools
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Life is less than 100 forms
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Poor to average accuracy
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Preferred option for larger, semi-permanent tools
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Good for 700-1300 forms depending on foam used
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Average to good accuracy
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Permanent, unlimited forms
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Used for automated, high-volume production
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Good to excellent accuracy
TYPES OF CUTTING
The type of cut used impacts the cost and speed of the finishing process. Vertical or horizontal cuts are relatively fast and easy, able to finish hundreds of parts per hour. More complex custom cuts or hole cutouts will slow down the finishing process and increase labor costs.
- Most common cut
- Creates a lip around the part a specified distance from the wall
- Recommended minimum lip of 1/16”
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Second most common cut
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Cuts the wall at a specified height
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Primarily used for aesthetics or for fitting parts together
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Holes of most shapes can be cut out of a flat surface
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Generally requires a small radius when used in corners (1/8” recommended, 1/16” achievable)
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May require additional tooling
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Varies from a multi-height horizontal cut to a complex, organic cut across multiple surfaces
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Increases labor and time depending on complexity
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May require additional tooling
TYPES OF FINSHING
Custom finishes are a great way to add improved aesthetics and functionality to thermoformed products. 3D Restoration offers several finishing options for your thermoformed parts.
- A clear ESD coating that can go on a few plastics including PETG, ABS and PVC
A clear abrasion-resistant coating (expensive)
A clear coat (matte or gloss) that extends the life of plastics in outdoor applications
Adds light diffusion to clear part or high-quality matte texture to opaque parts