【Pressure Forming】 Automated Post-Processing Guide for Thermoformed Parts!
Discover proven methods for automated post-processing of thermoformed parts.
If you're using thermoformed parts made with the Mayku Multiplier, you'll need some manual or automated post-processing to achieve the desired surface finish. Manual post-processing methods were introduced in a previous article:
👉 【Related Article】：Tool Guide for Manual Post-Processing of Thermoformed Parts!
This time, we will explore two different automated post-processing workflows, as well as the advantages and limitations of each, to give you a deeper understanding!!
You might be wondering what the Mayku Multiplier pressure former is. The following article will help you understand it better!
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CNC Workflow
CNC milling machines are an effective way to streamline post-processing, but they require some forward planning.
CNC Milling Machine
The accuracy of CNC work depends on precisely documenting the physical object being processed in CAD software. You need to align the form with its corresponding digital model or reference points to create a precise and consistent relationship between the two. There are many ways to do this:
Physical Registration Points
With a CNC machine, you can create holes that match the part's shape. These holes can be used with pins or screws to attach the part, aligning them with specific points on the template. This ensures proper fit and alignment between the part and the template, leading to accurate and consistent results in post-processing.
Milling a Border Around the Mold
Adding a border around the mold ensures proper alignment and stability of the part during post-processing. This prevents any accidental movement or misalignment.
Additionally, borders can be milled on both sides of the part using reversible inserts or by swapping them. This is particularly useful when complex details or features require processing on both sides. By employing reversible inserts or strategic swapping, you can achieve precise and accurate results while maintaining the desired level of detail and quality.
Milling Fixtures that Fit the Shape
Using fixtures and manufacturing aids can help operators save time and ensure accurate placement of parts, leading to efficient production. CNC machines are excellent tools for creating these aids. Placing the form within the fixture guarantees consistent registration points for every operation.
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Manufacturing Considerations
Accessibility
In some cases, parts may need to be milled from both sides to achieve complex details or features.
Mind the Fillets
Consider the size of the drill bit used, as it will affect the level of detail in the cut. A larger 8mm diameter drill bit will result in less detail and larger fillets compared to a smaller 2mm diameter drill bit.
Workpiece Fixturing
The vacuum bed of a CNC machine can be used to securely hold the template in place. If this is not feasible, alternative methods such as clamping the template or screwing it into a platen can be used.
Tip
Be sure to check your material and drill bit compatibility. For parts made with the Mayku Multiplier, a single flute end mill specifically designed for plastics is recommended.
【Related Products】：
1. Makera Carvera Desktop CNC Machine
2. Snapmaker CNC Machine
3. Roland CNC Machine
Laser Cutting Workflow
Laser cutting machines are extremely valuable tools that can complement the Mayku Multiplier, especially when consistency and accuracy are crucial. They offer significant advantages, particularly when handling larger production volumes, as they reduce the need for extensive manual labor.
Laser Cutting Machine
To achieve successful laser cutting, consistent part positioning throughout the cutting process is essential. This alignment is crucial for matching the part's position with the laser path. Follow these steps to ensure success:
1. Design the Cutting Path
In your design software, create a precise cutting path that matches the desired shape of the part. This path should be accurately aligned with the digital model or reference points to achieve the desired result.
2. Form the Part with Mayku Multiplier
Thermoform the part using the Mayku Multiplier, ensuring its shape conforms to the intended design.
3. Roughly Cut the Part
Use a band saw or similar tool to roughly cut the part, providing a basic shape for further laser cutting. You can also use the cutting techniques detailed in our manual post-processing guide.
4. Create a Flat Laser Cutting Fixture
Design a flat fixture that can be securely attached to the laser cutting machine bed. This fixture serves as a guide for consistent part positioning during cutting. For added stability, consider using a 3D printed fixture to securely hold the part within the frame.
5. Align the Part to be Cut
Place the thermoformed part into the laser cutting fixture, ensuring perfect alignment with the cutting path. Take necessary precautions to keep the part in the same position throughout the cutting process.
6. Initiate the Laser Cutting Process
Once confident with the alignment, initiate the laser cutting machine, allowing it to precisely cut the part along the specified path and remove the part from the sheet. This procedure can be repeated for larger batches.
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Manufacturing Considerations
Non-Contact Cutting
Since laser cutting is a non-contact technique, there is less possibility of part movement during cutting compared to CNC workflows.
Acrylic is the Clear Winner
PMMA (acrylic) is a plastic that is very suitable for laser cutting. Laser-cut acrylic produces clear and smooth cut edges without the need for further post-processing.
Beware of ABS
Laser cutting ABS is not recommended. This is because it releases toxic fumes when cut. It can also ignite, and as the material melts, the quality of the cut edge tends to deteriorate, resulting in uneven edges.
Check Your Part Height
Make sure to find a laser cutting machine with a bed that can be lowered enough to accommodate the height of your parts.
Streamline Your Thermoforming Operations with Automated Post-Processing Techniques
By automating the post-processing of parts produced by the Mayku Multiplier, you can optimize your thermoforming operations. Whether you are producing one-off parts or batch thermoformed parts, implementing registration techniques, milling borders, and fixtures will provide you with consistent quality and accuracy, saving you time in the long run.
【Related Products】：
1. Snapmaker Laser Engraving/Cutting Machine
2. Wisely Laser Engraving/Cutting Machine
3. Thunder Laser Laser Processing Machine
Explore Mayku's range of proven thermoforming materials to find the best fit for your workflow!
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