【Pressure Forming】How to achieve small-batch production? Mayku Multiplier Workflow Guide
The Mayku Multiplier is touted as "the world's first desktop pressure former"! Unlike traditional vacuum forming, it uses pressure to tightly conform a plastic sheet to the mold surface, while 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 components," "household appliances,", and "automotive parts."
If you are a 'personal studio,' 'creator,' 'artist,' etc., and are 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 will demonstrate the pressure forming workflow from concept to final part using the Mayku Multiplier. It is 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" separately.
Step 1: Design Template
First, you need a template 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 easier it is to remove the formed sheet from the template.
The primary consideration when designing for thermoforming: draft angles
Avoid undercuts, 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 molds made with EVA material sheets on the Mayku Multiplier
For non-porous templates, it is recommended to design air holes to allow air to escape as the material sheet forms in the internal space, preventing any trapped air.
Checking thermoforming template
Step 2: Template Manufacturing
Congratulations on completing your template design; next is the template manufacturing. You can use various techniques to create templates, including CNC milling machines and laser engraving/cutting machines. When manufacturing a template, ensure it has high-temperature resistance and strength, as it needs to withstand the pressure forming process. In this case, we used high-temperature resin to create the template.
High-temperature resin thermoforming template made with SLA 3D printing
Step 3: Material Selection
Once the template is ready, choose the material to be formed. Mayku offers a range of extended materials, all tested to ensure a smooth forming process.
Material sheets for 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 a PETG material sheet
In this case, we will use a 4mm ABS sheet, which features 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
When the heating process is nearing completion, place the template on the forming area. You can place multiple objects on the forming area at once, or just one large template.
Placing the thermoforming template on the Mayku Multiplier's forming area
Mayku Multiplier heating up
If your template has complex design features that may make demolding more difficult, you might need to coat it with a release agent, such as dry PTFE.
Applying PTFE coating to a thermoforming template
The Multiplier will heat the material to the optimal temperature. When the indicator on the screen 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. During the pressure release, you will hear the pressure being discharged. After the cooling process is complete, the air in the pressure chamber will be released. Now unlock and open the Multiplier.
Mayku Multiplier forming completion screen
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 circular saws, drills, or rotary power tools are strongly recommended.
Post-processing of formed parts with a circular saw
Additionally, if you are using the Mayku Multiplier for small-batch production, consider creating a jig for quick and precise post-processing of parts.
Checking car parts made with Mayku Multiplier
Using a pressure former, you can create high-quality, highly detailed parts in less time, with complete control over the entire process. It is ideal for producing precise prototypes, molds, or parts for final use.
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 post-processing techniques.
About the Mayku Multiplier
The Mayku Multiplier is an intuitively designed desktop pressure former that allows you to create precise prototypes, molds, and final parts with ultra-fine detail. It can capture surface details down to one micron, including surface textures, layered surfaces, and other features. With dimensions of only 685 x 600 x 600mm, a pressure forming capability of up to four tons, and a forming area of 400mm x 160mm, its design and controls make operation simple and enable rapid production of finished products.
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