【3D Printing Knowledge】A Tool Guide for Manual Post-Processing of Thermoformed Parts!
What tools should you use when you need to manually post-process thermoformed parts? In this guide, we'll explore different manual post-processing workflows and tools you can use to trim and finish your parts!
Manual Post-Processing Tools
Scissors
Scissors are a versatile tool for free-cutting thin materials such as EVA 1.5mm or HIPS 1mm. They are especially useful for cutting thin materials that do not require guides or templates. Due to their ease of use and accessibility, scissors are an essential addition to your post-processing toolkit!
Manual Post-Processing Tools
Scissors
Scissors are a versatile tool for free-cutting thin materials such as EVA 1.5mm or HIPS 1mm. They are especially useful for cutting thin materials that do not require guides or templates. Due to their ease of use and accessibility, scissors are an essential addition to your post-processing toolkit!
EVA 1.5mm Post-Processing 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 UHMW). To cut parts made from UHMW, first use a bandsaw, then use Kevlar scissors for a second cut. Finally, sand 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 UHMW). To cut parts made from UHMW, first use a bandsaw, then use Kevlar scissors for a second cut. Finally, sand 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, wearing protective equipment and operating in a well-ventilated area are also crucial for 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, wearing protective equipment and operating in a well-ventilated area are also crucial for 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 touch-ups.
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 touch-ups.
Cutting 1mm HIPS with a Scalpel
Handheld Rotary Power Tool (Dremel)
Handheld rotary power tools like Dremel come with a variety of attachments suitable for various situations, including cutting and processing parts. Cutting discs can be used to cut thin materials, while sanding attachments can remove excess material from thicker parts.
For example, ABS automotive parts are first post-processed with a bandsaw to remove excess material, then machined 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 such as a Dremel or ultrasonic cutter for greater 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 would first process with a bandsaw twice: once to remove excess material and a second time to get closer to the contour. Then, sand 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 such as a Dremel or ultrasonic cutter for greater 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 would first process with a bandsaw twice: once to remove excess material and a second time to get closer to the contour. Then, sand the edges with a Dremel for a more consistent finish.
Removing excess material from thermoformed 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 thermoformed parts (white) with high precision by 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 thermoformed parts (white) with high precision by using a 3D printed jig (black).
Manual Post-Processing Examples
Here are some post-processing workflows tested with different materials.
Here are some post-processing workflows tested with different materials.
HIPS
HIPS sheets are 1mm thick, making them easy to post-process. After forming a blister packaging prototype, remove excess material with Kevlar scissors, then use a 3D printed jig and cutter to trim the edges and achieve a consistent finish.
HIPS sheets are 1mm thick, making them easy to post-process. After forming a blister packaging prototype, remove excess material with Kevlar scissors, then use a 3D printed jig and cutter to trim the edges and achieve a consistent finish.
TIP: A bandsaw can be used as an alternative, but using Kevlar scissors produces no dust and requires 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, a cutter, or a scalpel.
If you are creating a two-part mold with EVA, consider placing a sheet of paper under the template as a base layer. This will create a permeable flat layer and prevent the EVA from retaining the pit pattern created 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, a cutter, or a scalpel.
If you are creating a two-part mold with EVA, consider placing a sheet of paper under the template as a base layer. This will create a permeable flat layer and prevent the EVA from retaining the pit pattern created by the Mayku forming sheet.
Two-part mold made with EVA 1.5mm on Mayku Multiplier
PMMA (Polymethyl Methacrylate)
PMMA has excellent mechanical and optical properties. For better accuracy, we recommend cutting first with a bandsaw and then with an ultrasonic cutter. Finish with a Dremel with a sanding attachment and hand sand with high-grit sandpaper for optimal results.
If you want the part to be perfectly transparent, you will need to sand and polish the template before forming. To eliminate fine scratches, you can use a plastic polish on the final part.
PMMA has excellent mechanical and optical properties. For better accuracy, we recommend cutting first with a bandsaw and then with an ultrasonic cutter. Finish with a Dremel with a sanding attachment and hand sand with high-grit sandpaper for optimal results.
If you want the part to be perfectly transparent, you will need to sand and polish the template before forming. To eliminate fine scratches, you can use a plastic polish on the final part.
Carlight component made with PMMA on Mayku Multiplier
UHMW (Ultra-High Molecular Weight)
UHMW 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 do not work well on this material. To finish the edges, you can sand with sandpaper, or use a scalpel and jig to cut.
UHMW 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 do not work well on this material. To finish the edges, you can sand with sandpaper, or use a scalpel and jig to cut.
UHMW prototype for protective gear 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 automotive component manufactured with Mayku Multiplier
Post-Processing Cheatsheet
In the table below, you can see the compatibility of some materials with the different post-processing tools introduced in this guide.
In the table below, you can see the compatibility of some materials with 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 "3D Printing Services", "3D Scanning Services", and "3D Spatial Scanning Services"!
Follow our fan page for the latest updates:
Facebook: https://www.facebook.com/3dmart.com.tw/
Instagram: https://www.instagram.com/3dmart
LinkedIn: https://www.linkedin.com/company/3dmart/
Reference