【3D Printing Knowledge】 Application Guide for Creating Thermoforming Molds with FDM 3D Printing

Thermoforming templates can be produced using various manufacturing methods, including Fused Deposition Modeling (FDM) 3D printing. In the previous two articles, we explored the technologies of SLA and SLS for manufacturing thermoforming templates, as well as their advantages and applications.

Click here to view related articles:
1) Application Guide for Creating Thermoforming Templates with SLS 3D Printing
2) Application Guide for Creating Thermoforming Templates with SLA 3D Printing

In this article, we will delve into the advantages of using filament 3D printing for thermoforming templates in more detail. We will also provide best practices and useful tips. By understanding the potential of this technology and its applications in the thermoforming industry, you can make informed decisions when choosing the most suitable template manufacturing method!
 

As with the previous two articles, let's start by introducing what this technology is all about!

What is Filament 3D Printing?
Filament 3D printing is an additive manufacturing technology that uses a continuous filament of thermoplastic material to create 3D objects. The process involves melting and extruding the material layer by layer, building the object from the bottom up.

The technology behind filament 3D printing is called FDM (Fused Deposition Modeling) or FFF (Fused Filament Fabrication). Today, these two terms are used interchangeably as they refer to virtually the same manufacturing process.

Compared to other additive manufacturing technologies, FDM parts are produced faster and at a lower cost, though quality and performance can vary. FDM 3D printers are also compatible with a wide range of materials, allowing for a broad spectrum of applications.

Designing and Manufacturing Thermoforming Templates
Here are some things to consider and recommended methods when designing and manufacturing thermoforming templates using filament 3D printing.

Layer Height
As with all 3D printing technologies, the thinner the layers, the smoother the surface. For thermoforming templates manufactured using filament 3D printing, we recommend a layer height between 0.1 and 0.2 mm to create templates with a subtle layered texture. This will significantly improve the demolding experience.

If you are making large prototype templates without vertical walls, you can increase the layer height, but it is always recommended to test it.

Template Draft Angle
We recommend a template draft angle of at least 5° for optimal forming and demolding. However, templates made with filament 3D printing have a more textured surface, making the demolding process more difficult compared to templates with smooth surfaces. If you cannot increase the draft angle of the template, consider sanding or smoothing the template surface before forming.

Nozzle Diameter
Most filament 3D printers come with a standard 0.4 mm nozzle. If you need to make small templates with high precision or small design features, you can use a 0.25 mm nozzle. However, if you are making large, simple templates, you should consider upgrading to a larger 0.8 mm nozzle. This will make your 3D prints faster and produce more durable templates.

Shell Thickness
Large, hollow templates are prone to deformation during forming under pressure and heat, especially when using a powerful pressure former like the Multiplier. To increase template strength, we recommend making a template with a shell thickness of 3-5 mm. It is best to test with different thicknesses to find the right one.

When making a thermoforming template, the thickness of the top plays a very important role, as it is in contact with the thermoplastic sheet for the longest time. Consider increasing the thickness of the top section to match the vertical wall thickness to prevent deformation due to pressure and heat.

Infill Density
Higher infill density results in stronger wear resistance of the part, making it the best choice for any project. An infill density of 50% is recommended, but testing is highly advised.

High infill density ensures that the part has sufficient strength to withstand pressure and heat, and also ensures that the part can be reused, making it ideal for projects that require a lot of testing.

Air Hole Size
We recommend using tapered air holes. These holes should not exceed 0.4 mm in diameter on the template surface and 2 mm in diameter at the base of the template.

Using larger nozzles and composite materials may slightly affect the tolerances of the 3D printer. Therefore, we recommend testing your 3D printer to ensure that the air holes are not blocked when printing with standard settings.

Draft Shield
When using 3D printing with engineering materials to create thermoforming templates, it is recommended to add a draft shield when preparing the 3D printed model. This will help reduce warping and ensure better overall part quality.

Recommended Filament Materials
When using filament 3D printing to create thermoforming templates, we recommend using engineering materials such as Ultimaker Nylon, which offers high thermal stability, high heat deflection temperature, and high tensile strength.

While thermoforming templates made with other filament materials (such as ABS, PETG, or HIPS) are compatible with Mayku's 3D formers (such as the Mayku FormBox), they tend to be most suitable for early prototyping. However, the final templates should be made using engineering materials, as they have better mechanical properties.