【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 SLA and SLS technologies for manufacturing thermoforming templates, along with 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 deeper into the advantages of using filament 3D printing for producing thermoforming templates. We will also provide best practices and helpful 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!
 

Just like the previous two articles, let's start by introducing what this technology is!

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 known as 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, but with varying quality and performance. 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 considerations and recommended methods when designing and manufacturing thermoforming templates using filament 3D printing.

Layer Height
As with all 3D printing technologies, thinner layers result in smoother surfaces. For thermoforming templates manufactured using filament 3D printing, we recommend a layer height between 0.1 to 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 minimum draft angle of 5° for optimal molding 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 template's draft angle, consider sanding or smoothing the template surface before forming.

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

Shell Thickness
Large, hollow templates can deform under pressure and heat during forming, especially when using powerful pressure forming machines like the Multiplier. To increase template strength, we recommend creating a template with a shell thickness of 3-5 mm. It's best to test different thicknesses to find the right one.

When making thermoforming templates, the top thickness plays a crucial role because it is in contact with the heated plastic 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 leads to greater wear resistance of the part, making it the optimal choice for any project. An infill density of 50% is recommended, but testing is strongly 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 requiring extensive testing.

Vent Hole Size
We recommend using conical vent holes. These vent holes should not exceed 0.4 mm in diameter on the template surface and not exceed 2 mm in diameter at the template base.

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 vent holes are not blocked when printing with standard settings.

Draft Shield
When using engineering materials for 3D printing to create thermoforming templates, it is recommended to add a draft shield when preparing the 3D print 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 forming machines (like the Mayku FormBox), they are often best suited for early prototyping. However, final templates should be made from engineering materials due to their superior mechanical properties.