Take Template Creation to the Next Level
High-quality templates make or break a thermoforming project. When designing and producing templates, it is crucial to acquire the knowledge necessary for best practices in thermoforming. Here, we will provide a detailed introduction to how you can use SLS 3D printing technology to create high-quality thermoforming templates!
What is Thermoforming?
Thermoforming is a common manufacturing process that creates specific shapes by heating a plastic sheet and molding it against a mold. One of the key steps in thermoforming is creating the template used to shape the plastic sheet.
First, Let’s Understand SLS 3D Printing!
Selective Laser Sintering (SLS) is a type of 3D printing technology, and it is an additive manufacturing process that belongs to the powder bed fusion family. It uses a high-power laser to fuse tiny plastic powder particles. Unlike other 3D printing technologies, SLS does not require support structures because the powder itself acts as the support material. The material used in SLS powder sintering is a granular thermoplastic polymer, which realizes extremely high design freedom and precision, while also enabling the production of parts with excellent, stable mechanical properties.
The SLS 3D Printing Process
With the video above and this brief explanation, we hope you have grasped the basics. So, what are the advantages of using SLS 3D printing? Here are some benefits specifically related to SLS 3D printing and the production of thermoforming templates:
Internal Porosity for Higher Quality Molding
One of the main benefits of using SLS 3D printing technology to produce thermoforming templates is that the resulting parts are porous. What is the advantage of this? Being porous eliminates the need to add vent holes to the template, or allows for the number of necessary vent holes to be significantly reduced. This is extremely important for thermoforming templates. Too many vent holes can lead to air bubbles or deformation in the plastic sheet during the forming process. Therefore, by reducing vent holes, you can produce higher-quality prints, improve the stability of the finished product, and save time!
Excellent Material Properties
SLS 3D printing typically uses nylon. Nylon is an ideal material for producing thermoforming templates because it possesses excellent mechanical properties and heat resistance.
Perfect for Producing Complex Parts
SLS 3D printing technology is particularly well-suited for producing complex parts. Because the laser can be directed to various spots during printing, a high level of detail can be reproduced. Furthermore, SLS 3D printing does not require support materials, as the powder itself functions as support, eliminating the need to use other materials. This increases design freedom and allows for the manufacture of more complex parts.
Now that we have introduced SLS 3D printing and its benefits, we will provide a detailed explanation of the process and precautions for actually creating thermoforming templates.
Design and Production of Thermoforming Templates
Here are some points to keep in mind when creating thermoforming templates with SLS 3D printing:
Part Orientation
When designing a thermoforming template for SLS 3D printing, you need to consider the orientation of the part on the build platform. This is because the temperature of the powder varies depending on the part's location, which can cause warping.
When designing a wide and relatively flat template, it is recommended to 3D print it at a slight angle of about 20º to minimize warping.
Post-Processing and Surface Finishing
While SLS 3D printing technology excels at manufacturing parts with complex shapes that do not require vent holes, the surface of the built parts is typically rough. This is where media blasting comes in. We strongly recommend performing a full powder-removal process using media blasting* on SLS parts to achieve a smoother surface finish.
*Media blasting is a processing method for surface cleaning and preparation in various repair, restoration, and coating applications. Abrasive media is sprayed onto the surface at high speed.
Also, depending on the application and needs, you can sand or coat the templates to achieve different surface finishes. This allows for even more customization. However, please note that changing the template surface can affect its porosity, which may influence the final results of the thermoforming process.
Recommended SLS Materials for Thermoforming
Nylon 12 is the most commonly used SLS 3D printing material and is also an ideal material for creating thermoforming templates, as it possesses excellent mechanical properties and heat resistance. The heat deflection temperature of Nylon 12 is 171ºC (0.45MPa), and the tensile strength is 50MPa. Also, because parts made with this material are porous, you do not need to provide vent holes in the template or reduce the number of holes, making it more convenient to use!
Applications for SLS Thermoforming Templates
SLS 3D printing has many benefits for thermoforming applications due to its unique part properties:
• Final Parts: SLS templates have excellent strength and heat resistance, and can also achieve high dimensional accuracy. Therefore, they are well-suited for the production of high-quality final parts.
• Small-Batch Production: SLS templates often have a longer lifespan than templates produced with other 3D printing technologies, making them ideal for creating templates that are used repeatedly in small-batch production.
• Complex Shapes: In addition to the high-precision build enabled by the laser, since the powder itself can be used as a support material, SLS 3D printing technology can create thermoforming templates with complex shapes.
View SLS Products
- Contact Us -
Please feel free to contact us for more detailed information about filaments and 3D printers! We will support you in making the best choice according to your needs!
3DMart offers more than just 3D printing. We provide three contract services: "3D Printing Service", "3D Scanning Service", and "Spatial 3D Scanning Service"!!
Follow us to check the latest information:
Facebook : https://www.facebook.com/3dmart.com.hk/
Instagram : https://www.instagram.com/3dmart
LinkedIn : https://www.linkedin.com/company/3dmart/
Reference