Successful thermoforming heavily depends on a tool that is well-suited to the task at hand. Tools themselves, however, will differ depending on the manufacturing method used to create them. In this article, we’ll take a look at several popular manufacturing methods – such as 3D printing technologies – that can be used to create thermoforming tools, as well as a few points to consider about each.

Additive manufacturing

Additive manufacturing, also known as 3D printing, is the process of creating a 3D object from a digital model. It is done layer by layer – hence “additive” – typically with a material such as plastic, resin, or powder.

FDM 3D printing (filament)

Fused Deposition Modeling (FDM) 3D Printing is an additive manufacturing technology in which layers of materials are fused together. The material – in the form of plastic or composite filament – is first heated, then extruded following a pattern, creating an object layer by layer.

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Ultimaker S5 (left) and Mayku FormBox (right)

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FDM 3D printed templates on a Mayku FormBox