【Vacuum Forming Application】Mayku FormBox Vacuum Forming and Mold Making Beginner's Guide! 7 Design Considerations You Should Know!
Before getting started, we hope you have a thorough understanding of the basic design principles of vacuum forming and mold making. This time, we've invited digital manufacturing expert Agustín Arroyo to explain it all.
Before using any equipment, it is essential to understand the design principles of the Mayku FormBox for vacuum forming. Similar to 3D printing, it's best to understand some design logic before you start designing. This knowledge can then be easily applied to 3D printed products or enclosures for electronic products, among other things.
No Undercuts
If you vacuum form a model with protruding parts or indentations, you won't be able to remove the object once the material sheet cools down. If you're used to FDM 3D printers, you'll know that undercuts must be avoided. When 3D printing objects for vacuum forming, all undercuts must be avoided.
No Undercuts
If you vacuum form a model with protruding parts or indentations, you won't be able to remove the object once the material sheet cools down. If you're used to FDM 3D printers, you'll know that undercuts must be avoided. When 3D printing objects for vacuum forming, all undercuts must be avoided.
Add Draft Angles
In plastic injection molding, draft angles are usually applied to the model's surface to facilitate the easy removal of the molded plastic part from the mold. If the model has infinite height, it will become a cone.
In plastic injection molding, draft angles are usually applied to the model's surface to facilitate the easy removal of the molded plastic part from the mold. If the model has infinite height, it will become a cone.
3D Printing Layer Lines
Due to the manufacturing process, 3D printed objects often have unique surface textures. Even if many materials visually hide layer lines, they are still present, and the FormBox is excellent at picking up these textures.
Due to the manufacturing process, 3D printed objects often have unique surface textures. Even if many materials visually hide layer lines, they are still present, and the FormBox is excellent at picking up these textures.
If you want a smooth surface on your mold, the first thing is to 3D print with thin layers. 3D printing with 0.1mm layers will produce a smoother surface. However, if you want a perfect surface, you will need to post-process the part. Using filler and sanding is the simplest method, though this method is not suitable for small details. Sandblasting might be a better option.
Avoid Sharp Angles
Due to the manufacturing process, vacuum forming is not suitable for objects with sharp angles. The main reason is that the plastic sheet may fold back on itself at sharp edges, reducing the quality of the molding.
Avoid Sharp Angles
Due to the manufacturing process, vacuum forming is not suitable for objects with sharp angles. The main reason is that the plastic sheet may fold back on itself at sharp edges, reducing the quality of the molding.
For example, if a star-shaped object is used as a template, the tips of the star may produce webbing because the angles are very sharp. On the other hand, a pentagonal template or a star template with rounded corners will produce high-quality molds because there are no sharp angles.
Chamfer All Edges
In plastic injection molding, chamfering the edges of a model is common. Chamfering not only improves ergonomics but also helps the model release from the plastic sheet. A 2mm chamfer can reduce webbing and improve the surface finish of the mold.
Chamfer All Edges
In plastic injection molding, chamfering the edges of a model is common. Chamfering not only improves ergonomics but also helps the model release from the plastic sheet. A 2mm chamfer can reduce webbing and improve the surface finish of the mold.
Add Air Holes
The better the airflow, the more detail the mold will have. When the material sheet is deposited on the object, there is a very small time window during which the material sheet is hot enough and air is moving. We want the air to flow as quickly as possible, as this will allow the material sheet to capture better detail.
The better the airflow, the more detail the mold will have. When the material sheet is deposited on the object, there is a very small time window during which the material sheet is hot enough and air is moving. We want the air to flow as quickly as possible, as this will allow the material sheet to capture better detail.
If there are areas in your mold design where air might get trapped, it is recommended to add small holes where the air can move. A 1mm hole is barely visible on the mold but will significantly improve the mold's quality.
Object Height and Width
The maximum mold size that can be made with the FormBox is determined by the complexity of the overall shape. A little trick is that wide objects are easier to form than tall objects.
Object Height and Width
The maximum mold size that can be made with the FormBox is determined by the complexity of the overall shape. A little trick is that wide objects are easier to form than tall objects.
If all factors have been considered, the FormBox can still form tall objects. Generally, it is recommended to use objects that are wider than they are tall or to use larger draft angles in combination.
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Did you enjoy this sharing? 3DMart offers more than just 3D printing. Contact us now to learn more about vacuum forming applications.
Follow our Facebook page to stay updated: https://www.facebook.com/3dmart.com.tw/
https://www.instagram.com/3dmart/
Reference