Step 1: Design a Template <br>First, you need a template that can give the molded plastic sheet a precise shape. Designers need to consider the tilt angle, as these will make the demolding process easier. The greater the tilt angle, the easier it is to remove the molded sheet from the template.
Grooves should be avoided because once the plastic sheet cools down, you won't be able to remove the object. However, using Mayku's soft EVA material sheets, you can create parts with small grooves.
For non-porous templates, it is recommended to design air holes to allow air to escape as the material sheet forms within the internal space, without trapping any air inside.
Step 2: Create a template
Congratulations on completing the template design! The next step is template manufacturing. You can use various technologies to manufacture templates, including CNC milling machines and laser engraving/cutting machines . When manufacturing the template, ensure it has high-temperature resistance and strength, as it needs to withstand the pressure molding process. In this case, we used high-temperature resin to make the template.
Step 3: Selecting Materials
Once the template is ready, select the material to be molded. Mayku offers a range of expanded materials, all of which are tested to ensure a smooth molding process.
Some materials (such as PETG) have a protective film, so be sure to remove the protective film before putting the material into the machine.
In this case study, we will use a 4mm ABS platform, which has high hardness, excellent impact resistance and chemical resistance.
Step 4: Molding process
Now it's time to use the Mayku Multiplier for molding. Open the machine cover and place the material on top.
Close the lid and turn the top locking device to secure the material in place. Once the material is in place, you will hear the gas tank below the molding area compressing. The heating process will begin automatically, and the gas tank will compress simultaneously.
When the heating process is almost complete, place a template on the forming area. You can place multiple objects on the forming area at the same time, or just one large template.
If your mold has complex design features, it may make demolding more difficult, and you may need to apply a release agent, such as dried polytetrafluoroethylene (PTFE).
The multiplier will heat the material to the optimal temperature. When the indicator on the screen shows that the machine is ready, close the lid and slide the bottom locking device to prepare for molding.
Press the button to release five tons of pressure into the molding zone. You will hear the sound of pressure being released during the pressure release process. After the cooling process is complete, the air in the pressure chamber will be released. Now unlock and open the Multiplier.
Step 5: Post-processing
Once the final part is obtained, excess material needs to be removed. Depending on the material used and its thickness, there are several methods available. For thinner and more flexible materials, hand cutting with scissors or a knife works well. For thicker or harder materials, as in our case, power tools such as a circular saw, drill, or rotary power tool are strongly recommended.
In addition, if you are using Mayku Multiplier for small-batch production, you may consider making a fixture to allow for quick and accurate post-processing of parts.
Using a pressure forming machine, you can create high-quality, highly precise parts in less time and have complete control over the entire process. It is ideal for producing precision prototypes, molds, or parts that can be used for final products.
This innovative machine makes the process of manufacturing high-quality parts simple and intuitive. Hopefully, this guide will give you an understanding of how to use the Mayku Multiplier and post-processing techniques.
About Mayku Multiplier
The Mayku Multiplier is an intuitively designed benchtop pressure molding machine that allows you to create precise prototypes, molds, and final parts with ultra-fine detail. It can capture surface details up to one micrometer, including surface textures, layered surfaces, and other features. Measuring only 685 x 600 x 600 mm, it boasts a pressure molding capacity of up to four tons and a molding space of 400 mm x 160 mm. Its design and controls simplify operation and enable rapid production of finished products.
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