【Pressure Forming】Automated Post-Processing Guide for Thermoformed Parts!
Explore tried-and-tested methods for automated post-processing of thermoformed parts
If you're working with thermoformed parts made with the Mayku Multiplier, some manual or automated post-processing is required 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 provide you with a deeper understanding! !
You might be wondering what the Mayku Multiplier pressure former is? The following article will help you understand it better!
👉 【Related article】：Vacuum Forming vs. Pressure Forming, What's the Difference? Find Out Here!
CNC Workflow
CNC milling machines are an effective way to simplify post-processing, but require some foresight.
CNC Milling Machine
The accuracy of CNC work depends on accurately documenting the physical object being processed in CAD software. You need to align the form with the corresponding digital model or reference points to establish a precise and consistent relationship between the two. There are many ways to do this:
Physical Registration Points
Using a CNC machine, you can create holes that match the part's shape. These holes can be connected to the part using pins or screws, aligning them with specific points on the mold. This ensures proper fit and alignment between the part and the mold, resulting in 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.
Furthermore, the border can use reversible inserts or exchange them, allowing milling on both sides of the part. This is very useful when complex details or features require processing on both sides. By using reversible inserts or strategic exchanges, you can achieve precise and accurate results while maintaining the desired level of detail and quality.
Milling a Form-Fitting Fixture
Using fixtures and manufacturing aids can help operators save time and ensure accurate part placement, leading to efficient production. CNC machine tools are excellent for creating these aids. Placing the form within the fixture guarantees consistent registration points for each operation.
👉 【Related article】：Makera Carvera Desktop CNC Machine 4 Major Application Guide
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 affects 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 Fixtures
The vacuum bed of a CNC machine can be used to securely hold the mold in place. If this is not feasible, alternative methods such as clamping the mold or screwing it into a spoilboard can be used.
Tip
Always check the compatibility of your material with the drill bit. For parts made with the Mayku Multiplier, a single flute die specifically 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 valuable tools that 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 Cutter
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 aligns with the desired shape of the part. This path should be accurately aligned with the digital model or reference points to achieve the desired results.
2. Form the Part Using the Mayku Multiplier
Thermoform the part using the Mayku Multiplier, ensuring its shape matches the intended design.
3. Roughly Cut the Part
Roughly cut the part using a bandsaw or similar tool, 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 cutter bed. This fixture serves as a guide for consistently positioning parts for cutting. For added stability, consider using a 3D printed fixture to firmly 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 ensure the part remains in the same position throughout the cutting process.
6. Initiate the Laser Cutting Process
Once confident in the alignment, start the laser cutter, allowing it to precisely cut the part along the specified path and remove it from the sheet. For larger batches, this procedure can be repeated.
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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 a CNC workflow.
Acrylic is the Clear Winner
PMMA (acrylic) is a plastic that is very suitable for laser cutting. Laser-cut acrylic has crystal-clear and smooth cut edges, requiring no further post-processing.
Be Careful with 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 an uneven edge.
Check Your Part Height
Make sure to find a laser cutter with a bed that can descend low enough to accommodate the height of your part.
Streamline Your Thermoforming Operations with Automated Post-Processing Techniques
By automating the post-processing of parts produced with 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 precision, saving you time in the long run.
【Related Products】：
1. Snapmaker Laser Engraving/Cutting Machine
2. Wisely Laser Engraving/Cutting Machine
3. Thunder Laser Cutting Machine
Explore Mayku's range of proven thermoforming materials to find the best fit for your workflow!
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