【3D Printing Knowledge】A Guide to Tools for Manual Post-Processing Thermoformed Parts!
What tools should you use when manual post-processing thermoformed parts? In this guide, we'll explore different manual post-processing workflows and tools you can use to cut and finish your parts!
Manual Post-Processing Tools
Scissors
Scissors are a versatile tool for free-cutting thin materials like EVA 1.5mm or HIPS 1mm. They are particularly useful for cutting thin materials that don't require guides or templates. Due to their ease of use and availability, scissors are an essential addition to your post-processing toolbox!
Manual Post-Processing Tools
Scissors
Scissors are a versatile tool for free-cutting thin materials like EVA 1.5mm or HIPS 1mm. They are particularly useful for cutting thin materials that don't require guides or templates. Due to their ease of use and availability, scissors are an essential addition to your post-processing toolbox!
Post-processing EVA 1.5mm with scissors
Kevlar Scissors
Kevlar scissors are designed for cutting tougher and thicker materials that might damage regular scissors. They are particularly useful for cutting thicker, softer Mayku materials, such as Ultra-High Molecular Weight Polyethylene (UHMW). To cut parts made from UHMW, first use a bandsaw, then use Kevlar scissors for a second cut. Finally, deburr the edges with a file or sandpaper.
Kevlar scissors are designed for cutting tougher and thicker materials that might damage regular scissors. They are particularly useful for cutting thicker, softer Mayku materials, such as Ultra-High Molecular Weight Polyethylene (UHMW). To cut parts made from UHMW, first use a bandsaw, then use Kevlar scissors for a second cut. Finally, deburr the edges with a file or sandpaper.
Cutting 3mm UHMW with Kevlar scissors
Ultrasonic Cutter
When dealing with tough materials like PETG or PMMA, an ultrasonic cutter can make the task much smoother. To ensure optimal results, it is recommended to use a powerful ultrasonic cutter with a longer blade. Mastering the technique of using this cutter may require some practice, as attention must be paid to the blade's entry point and cutting angle to avoid dulling or melting the blade.
Since plastic fumes are emitted during this process, it is also crucial to wear protective equipment and operate in a well-ventilated area to ensure safety.
When dealing with tough materials like PETG or PMMA, an ultrasonic cutter can make the task much smoother. To ensure optimal results, it is recommended to use a powerful ultrasonic cutter with a longer blade. Mastering the technique of using this cutter may require some practice, as attention must be paid to the blade's entry point and cutting angle to avoid dulling or melting the blade.
Since plastic fumes are emitted during this process, it is also crucial to wear protective equipment and operate in a well-ventilated area to ensure safety.
Cutting 4mm ABS with an ultrasonic cutter
Scalpel
If you need to cut thin materials like EVA 1.5mm or HIPS 1mm, a scalpel can be a useful tool. They are particularly effective for achieving precise cuts and trims.
If you need to cut thin materials like EVA 1.5mm or HIPS 1mm, a scalpel can be a useful tool. They are particularly effective for achieving precise cuts and trims.
Cutting 1mm HIPS with a scalpel
Handheld Rotary Power Tool (Dremel)
Handheld rotary power tools like Dremels come with a variety of attachments suitable for various situations, including cutting and finishing parts. Cutting discs can be used for cutting thin materials, while sanding attachments can remove excess material from thicker parts.
For example, ABS car parts are first post-processed using a bandsaw to remove excess material, then processed and sanded with a Dremel to smooth the edges.
Bandsaw
A bandsaw is an essential tool for cutting rigid materials. It is a quick and reliable method for removing excess material and can be used in conjunction with more precise tools like a Dremel or ultrasonic cutter for higher accuracy.
If you don't have space for a bandsaw, a jigsaw can be a good alternative, offering similar results and material compatibility. For example, when cutting ABS parts, you first use a bandsaw for two passes: one to remove excess material and a second to get closer to the contour. Then, deburr the edges with a Dremel for a more consistent finish.
A bandsaw is an essential tool for cutting rigid materials. It is a quick and reliable method for removing excess material and can be used in conjunction with more precise tools like a Dremel or ultrasonic cutter for higher accuracy.
If you don't have space for a bandsaw, a jigsaw can be a good alternative, offering similar results and material compatibility. For example, when cutting ABS parts, you first use a bandsaw for two passes: one to remove excess material and a second to get closer to the contour. Then, deburr the edges with a Dremel for a more consistent finish.
Removing excess material from formed parts with a bandsaw
Jig-assisted Cutting
When post-processing thin parts (1-1.5mm), it can be helpful to design and create a jig to guide you during the cutting process. This jig can be made using 3D printing or other techniques.
In the example below, you can see how to cut formed parts (white) with high precision using a 3D-printed jig (black).
When post-processing thin parts (1-1.5mm), it can be helpful to design and create a jig to guide you during the cutting process. This jig can be made using 3D printing or other techniques.
In the example below, you can see how to cut formed parts (white) with high precision using a 3D-printed jig (black).
Manual Post-Processing Examples
Below are some post-processing workflows tested with different materials.
Below are some post-processing workflows tested with different materials.
HIPS
HIPS sheets are 1mm thick, making them easy to post-process. After forming blister packaging prototypes, remove excess material with Kevlar scissors, then use a 3D-printed jig and cutter to trim the edges and achieve consistent results.
HIPS sheets are 1mm thick, making them easy to post-process. After forming blister packaging prototypes, remove excess material with Kevlar scissors, then use a 3D-printed jig and cutter to trim the edges and achieve consistent results.
TIP : A bandsaw can be used as an alternative, but Kevlar scissors produce no dust and require no cleaning.
EVA
Due to EVA's flexible properties, small parts are extremely easy to demold, and parts can also be easily cut with scissors, cutters, or scalpels.
If you are making a two-part mold with EVA, consider placing a piece of paper as a base layer beneath the template. This will form a permeable flat layer and prevent the EVA from having the pitted pattern produced by the Mayku forming sheet.
EVA
Due to EVA's flexible properties, small parts are extremely easy to demold, and parts can also be easily cut with scissors, cutters, or scalpels.
If you are making a two-part mold with EVA, consider placing a piece of paper as a base layer beneath the template. This will form a permeable flat layer and prevent the EVA from having the pitted pattern produced by the Mayku forming sheet.
Two-part mold made with EVA 1.5mm on a Mayku Multiplier
PMMA (Polymethyl Methacrylate)
PMMA has excellent mechanical and optical properties. For better precision, we recommend first cutting with a bandsaw, then with an ultrasonic cutter. Finish with a Dremel with sanding attachments and hand-sand with high-grit sandpaper for best results.
If you want completely transparent parts, you will need to sand and polish the template before forming. To eliminate fine scratches, a plastic polishing agent can be used on the final part.
PMMA has excellent mechanical and optical properties. For better precision, we recommend first cutting with a bandsaw, then with an ultrasonic cutter. Finish with a Dremel with sanding attachments and hand-sand with high-grit sandpaper for best results.
If you want completely transparent parts, you will need to sand and polish the template before forming. To eliminate fine scratches, a plastic polishing agent can be used on the final part.
Carlight part made with PMMA on a Mayku Multiplier
UHMW (Ultra-High Molecular Weight Polyethylene)
Ultra-High Molecular Weight Polyethylene is an excellent non-friction material, but that doesn't mean it can't be post-processed. We recommend using Kevlar scissors, a bandsaw, or a scalpel to cut this material. Please note that ultrasonic cutters are not very effective on this material. To finish the edges, you can sand them or use a scalpel and a jig for cutting.
Ultra-High Molecular Weight Polyethylene is an excellent non-friction material, but that doesn't mean it can't be post-processed. We recommend using Kevlar scissors, a bandsaw, or a scalpel to cut this material. Please note that ultrasonic cutters are not very effective on this material. To finish the edges, you can sand them or use a scalpel and a jig for cutting.
UHMW protective gear prototype made with Mayku Multiplier
ABS
4mm ABS can be post-processed using many of the tools mentioned in this guide. Although automatic processing such as CNC can also be used, excess material is best removed with a bandsaw or ultrasonic cutter.
For finishing, we recommend sanding with a Dremel or by hand, and trimming with a scalpel.
4mm ABS can be post-processed using many of the tools mentioned in this guide. Although automatic processing such as CNC can also be used, excess material is best removed with a bandsaw or ultrasonic cutter.
For finishing, we recommend sanding with a Dremel or by hand, and trimming with a scalpel.
ABS car part manufactured with Mayku Multiplier
Post-Processing Cheatsheet
In the table below, you can see the compatibility between some materials and the different post-processing tools introduced in this guide.
In the table below, you can see the compatibility between some materials and the different post-processing tools introduced in this guide.
Has this detailed introduction helped you better understand manual post-processing of thermoformed parts? If you need more details, please feel free to contact us!
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3DMart offers more than just 3D printing; we provide three major OEM services: 「3D Printing Service」, 「3D Scanning Service」, and 「360° Space 3D Scanning Service」!!
Follow our fan page to stay updated:
Facebook : https://www.facebook.com/3dmart.com.tw/
Instagram : https://www.instagram.com/3dmart
LinkedIn : https://www.linkedin.com/company/3dmart/
Reference Material