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There are various manufacturing methods for producing thermoforming molds, and Fused Deposition Modeling (FDM) 3D printing is one of them. In our previous articles, we introduced the techniques, benefits, and applications of manufacturing thermoforming molds using SLA and SLS 3D printing.

Related articles:
1) A Guide to Using SLS 3D Printed Molds for Thermoforming
2) A Guide to Using SLA 3D Printed Molds for Thermoforming

In this article, we will take a closer look at the benefits of using filament 3D printing to produce thermoforming molds. We will also explain best practices and helpful tips. By understanding the potential of this technology and how it is applied in the thermoforming industry, you can gain the insights needed to choose the optimal mold manufacturing method for your application!
 

As with our previous 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. It builds the object layer by layer, melting and extruding the material from the bottom up.

Filament 3D printing technology is known as FDM (Fused Deposition Modeling) or FFF (Fused Filament Fabrication). These two terms are used interchangeably today, as they refer to virtually the same manufacturing process.

Compared to other additive manufacturing technologies, parts produced with FDM can be manufactured in less time and at a lower cost, though there are differences in quality and performance. Furthermore, because FDM 3D printers support a wide variety of materials, they can be utilized for a broad range of applications.

Design and Manufacture of Thermoforming Molds
The following are points to keep in mind and recommended methods for designing and manufacturing thermoforming molds using filament 3D printing.

Layer Height
As with all 3D printing technologies, thinner layers result in a smoother surface. When using filament 3D printing technology to produce thermoforming molds, we recommend a layer height of 0.1 to 0.2 mm to create a mold with a slight textured finish from the layers. This significantly facilitates the mold release process.

When producing large prototype molds that do not have vertical walls, you can use a larger layer height, but we recommend testing it beforehand.

Draft Angle for Molds
For optimal forming and mold release performance, we recommend a draft angle of at least 5°. However, molds produced via filament 3D printing have many visible layer lines on the surface, making them more difficult to release compared to molds with smooth surfaces. If you cannot increase the draft angle, consider sanding or smoothing the mold surface before forming.

Nozzle Diameter
Many filament 3D printers come standard with a 0.4 mm nozzle. For small molds with high precision or intricate design features, you can use a 0.25 mm nozzle. Conversely, for large and simple molds, you may want to consider switching to a larger 0.8 mm nozzle. This increases 3D printing speed and allows for the production of more durable molds.

Shell Thickness
Large, hollow molds are prone to deformation under pressure and heat during forming, and caution is required especially when using powerful pressure formers like the Multiplier. To increase the strength of the mold, we recommend a shell thickness of 3 to 5 mm. We recommend testing with different thicknesses to find the optimal one.

When producing thermoforming molds, the top thickness is crucial as it is the part that remains in contact with the thermoplastic sheet for the longest time. To prevent deformation caused by pressure or heat, consider increasing the top thickness to match the thickness of the vertical walls.

Infill Density
Higher infill density increases the wear resistance of the part. We recommend a 50% infill density as a setting suitable for all projects, but we strongly advise testing it beforehand.

By using a high infill density, you not only ensure the part has enough strength to withstand pressure and heat, but also allow for repeated use, which is particularly suitable for projects requiring numerous tests.

Vent Hole Size
We recommend using tapered vent holes. The diameter of the vent hole should be 0.4 mm or less on the mold surface side and 2 mm or less on the mold base side.

Using large nozzles or composite materials may slightly affect the tolerances of the 3D printer. Therefore, we recommend testing with your 3D printer beforehand to ensure that vent holes are not blocked when printed with standard settings.

Draft Shield
When using engineering materials to produce thermoforming molds via 3D printing, we recommend adding a draft shield when preparing the 3D printed model. This suppresses warping and improves the overall quality of the part.

Recommended Filament Materials
When producing thermoforming molds via filament 3D printing, we recommend engineering materials such as nylon from Ultimaker. These materials provide high thermal stability, higher heat deflection temperatures, and high tensile strength.

Thermoforming molds made from other filament materials such as ABS, PETG, and HIPS are also compatible with Mayku 3D formers such as the Mayku FormBox, but these are mainly suitable for early prototype production. We recommend using engineering materials for final molds due to their superior mechanical properties.