Exploring effective methods for automated post-processing of thermoformed parts
If you are working with thermoformed parts made by Mayku Multiplier , some manual or automatic post-processing is required to achieve the desired surface finish. The manual post-processing method was described in a previous article:
👉 [ Related Article]: A tool guide for manually post-processing thermoformed parts!
This time, we'll explore two different automated post-processing workflows, along with the advantages and limitations of each, giving you a deeper understanding!
You might be wondering, what is a Mayku Multiplier compression molding machine? The following article will help you understand!
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CNC Workflow
CNC milling machines are an effective way to simplify post-processing, but require some forward-looking planning.
CNC machining machine
The accuracy of CNC work depends on precisely recording the solid object being processed in the CAD software. You need to align the form with the corresponding digital model or reference points to establish a precise and consistent relationship between the two. There are many ways to do this:
Physical registration point
Using CNC machine tools, you can create holes that conform to the shape of the part. These holes can be connected to the part using pins or screws, aligning them with specific points on a template. This ensures proper fit and alignment between the part and the template, resulting in accurate and consistent results in post-processing.
The boundary around the milling die
Adding a border around the mold ensures proper alignment and stability of the parts during post-processing. This prevents any accidental movement or misalignment.
Furthermore, the borders can be reversibly inlaid or interchanged, allowing milling to be performed on both sides of the part. This is extremely useful when complex details or functions need to be addressed on both sides. By employing reversible inlays or strategic interchange, you can achieve precise and accurate results while maintaining the desired level of detail and quality.
Milling out a fixture of the appropriate shape
Using fixtures and manufacturing aids helps operators save time and ensures accurate part placement, thus enabling efficient production. CNC machine tools are excellent tools for creating these aids. Placing a form within the fixture ensures consistent registration points for each operation.
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Manufacturing Precautions
Accessibility
In some cases, parts may need to be milled from both sides to obtain intricate details or features.
Note the rounded corners
Consider the size of the drill bit you use, as it affects the level of detail in the cut. A larger drill bit with a diameter of 8 mm will result in less detail and a larger radius compared to a smaller drill bit with a diameter of 2 mm.
workpiece fixture
The template can be securely held in place using the suction head of a CNC machine tool. If this is not feasible, alternative methods can be used, such as clamping the template or screwing it into the autoclave plate.
tip
Please be sure to check the compatibility of your material with the drill bit. For parts manufactured by Mayku Multiplier , it is recommended to use a single-groove mold specifically designed for plastics.
[ Related Products]:
1. Makera Carvera benchtop CNC machining center
2. Snapmaker CNC machining machine
3. Roland CNC machining center
Laser cutting workflow
Laser cutters are invaluable tools that complement the Mayku Multiplier, especially when consistency and accuracy are paramount. They offer significant advantages, particularly when handling large production volumes, as they reduce the need for extensive manual labor.
Laser cutting machineFor successful laser cutting, consistent part positioning must be ensured throughout the entire cutting process. This alignment is crucial for matching the part's position with the laser path. Please follow these steps to ensure success:
1. Design the cutting path
In your design software, create precise cutting paths that match the required shape of the part. These paths should be accurately aligned with the digital model or reference points to achieve the desired result.
2. Use Mayku Multiplier to form parts.
Use Mayku Multiplier to thermoform parts to ensure their shape matches the intended design.
3. Roughly cut off part
Use a band saw or similar tool to roughly cut the part, providing a basic shape for further laser cutting. You can also use the cutting techniques detailed in our manual post-processing guide.
4. Create a planar laser cutting fixture
Design a flat fixture that can be securely attached to a laser cutting machine. This fixture will serve as a guide for consistently positioning parts during cutting. For increased stability, consider using a 3D-printed fixture to firmly hold the parts within a frame.
5. Align the parts to be cut.
Place the thermoformed part into the laser cutting fixture, ensuring perfect alignment with the cutting path. Take necessary precautions to ensure the part remains in the same position throughout the cutting process.
6. Start the laser cutting process
Once you are confident in the alignment, start the laser cutter and allow it to precisely cut the part along the specified path, then remove the part from the sheet metal. This procedure can be repeated for larger batches.
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Manufacturing Precautions
Non-contact cutting
Because laser cutting is a non-contact technology, the likelihood of parts moving during cutting is much lower compared to CNC workflows.
Acrylic is the clear winner.
PMMA (acrylic) is a plastic that is ideally suited for laser cutting. Laser-cut acrylic produces crystal-clear, smooth cut edges without the need for further post-processing.
Note ABS
Laser cutting of ABS is not recommended. This is because it releases toxic fumes during the cutting process. It can also be ignited, and as the material melts, the quality of the cut edges tends to deteriorate, resulting in uneven edges.
Check your part height
Make sure to find a laser cutter with a bed that can be lowered to a height sufficient to accommodate the parts.
Simplify your thermoforming operations with automated post-processing technology
By automating the post-processing of parts produced by the Mayku Multiplier, you can optimize your thermoforming operations. Whether you are producing one-off parts or batches of thermoformed parts, implementing registration technology, milling edges, and fixtures will provide you with consistent quality and precision, saving you time in the long run.
[ Related Products]:
1. Snapmaker Laser Engraving/Cut Machine
2. Wisely Laser Engraving/Cut Machine
3. Thunder Laser Processing Machine
Discover Mayku’s proven range of thermoforming materials and find the perfect material for your workflow!
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