【Pressure Forming】How to Achieve Small Batch Production? Mayku Multiplier Workflow Guide
The Mayku Multiplier is dubbed "the world's first desktop pressure former"! Unlike traditional vacuum forming, it uses pressure to tightly adhere plastic sheets to the mold surface, while also using a heat source to soften the plastic, which then cools and solidifies into shape. This pressure forming technique can be applied to complex three-dimensional shapes, such as "cosplay models," "aircraft parts," "household appliances," and "automotive components."
If you are a 'personal studio,' 'creator,' 'artist,' etc., looking for a way to produce precise prototypes, molds, or final product parts, then try the Mayku Multiplier! It allows you to quickly create precise finished products right in your office.
(* We demonstrate the pressure forming workflow from concept to final part using the Mayku Multiplier. It's important to note that each project is unique and may require different or additional steps.)
In this article, we will introduce the steps for creating an automotive prototype using the Mayku Multiplier, covering "Design Techniques," "Manufacturing and Forming," and "Post-Processing."
Step 1: Design the Mold
First, you need a mold that can give the formed plastic sheet a precise shape. Designers need to consider draft angles, as they make the demolding process easier. The larger the draft angle, the less difficult it is to remove the formed sheet from the mold.
The primary consideration when designing for thermoforming: draft angles
Grooves should be avoided, as once the plastic sheet cools, you won't be able to remove the object. However, with Mayku's soft EVA material sheets, you can create parts with small undercuts.
Soft mold made with EVA material sheets on the Mayku Multiplier
For non-porous molds, it is recommended to design air vents to allow air to escape as the material forms within the internal space, preventing any air from getting trapped inside.
Checking the thermoforming mold
Step 2: Fabricate the Mold
Congratulations on completing your mold design; next is the mold fabrication. You can use various techniques to fabricate molds, including CNC milling machines and laser engraving/cutting machines. When fabricating the mold, ensure it has high heat resistance and strength, as it needs to withstand the pressure forming process. In this case, we used high-temperature resin to create the mold.
High-temperature resin thermoforming mold created with SLA 3D printing
Step 3: Choose Materials
Once your mold is ready, choose the material you want to form. Mayku offers a range of extended materials, all tested to ensure a smooth forming process.
Material sheets compatible with Mayku Multiplier
Some materials (like PETG) have a protective film, so be sure to peel it off before placing the material into the machine.
Removing the protective film from PETG material sheet
In this case, we will use a 4mm ABS sheet, which offers high hardness, excellent impact resistance, and chemical resistance.
Placing a 4mm ABS sheet into the Mayku Multiplier
Step 4: Forming Process
Now it's time to form using the Mayku Multiplier. Open the machine lid and place the material on top.
Placing a 4mm ABS sheet into the Mayku Multiplier
Close the lid and turn the top locking device to secure the material in place. Once the material is in position, you will hear the air tank below the forming area compressing. The heating process will start automatically, and the air tank will compress simultaneously.
Mayku Multiplier heating up
As the heating process nears completion, place the mold on the forming area. You can place multiple objects on the forming area at once, or just one large mold.
Placing a thermoforming mold on the Mayku Multiplier forming area
Mayku Multiplier heating up
If your mold has complex design features that might make demolding more difficult, you may need to apply a release agent, such as dry polytetrafluoroethylene (PTFE).
Applying a PTFE coating to the thermoforming mold
The Multiplier heats the material to the optimal temperature. When the screen indicator shows the machine is ready, close the lid and slide the bottom locking device to prepare for forming.
Mayku Multiplier locking device
Press the button to release five tons of pressure into the forming area. You will hear the pressure being released during this process. After the cooling process is complete, the air in the pressure chamber will be released. Now unlock and open the Multiplier.
Mayku Multiplier forming complete screen display
Step 5: Post-Processing
After obtaining the final part, excess material needs to be removed. Depending on the material used and its thickness, there are various methods for this. For thinner and more flexible materials, manual cutting with scissors or a utility knife works well. If using thicker or harder materials, as in our case, power tools such as a circular saw, drill, or rotary power tool are highly recommended.
Post-processing formed part with a circular saw
Furthermore, if you are using the Mayku Multiplier for small-batch production, consider creating a jig to facilitate quick and accurate post-processing of parts.
Checking car parts made with Mayku Multiplier
Using a pressure forming machine allows you to create high-quality, highly detailed parts in a shorter amount of time, with complete control over the entire process. It is ideal for producing precise prototypes, molds, or parts suitable for final products.
This innovative machine makes the process of manufacturing high-quality parts simple and intuitive. We hope this guide has given you insight into how to use the Mayku Multiplier and its post-processing techniques.
About Mayku Multiplier
The Mayku Multiplier is an intuitively designed desktop pressure forming machine that allows you to create precise prototypes, molds, and final parts with incredible detail. It can capture surface details up to one micron, including surface textures, layered surfaces, and other features. With dimensions of only 685 x 600 x 600mm, up to four tons of pressure forming capability, and a forming area of 400mm x 160mm, its design and controls make operation simple, enabling rapid production of finished products.
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