[3D Printing Knowledge] A tool guide for manually post-processing thermoformed parts!
What tools should you use when manually post-processing thermoformed parts? In this guide, we'll explore different manual post-processing workflows and tools you can use to cut and finish your parts!
Manual post-processing tools
Scissors
Scissors are a versatile tool for freely cutting thin materials such as 1.5mm EVA or 1mm HIPS. They are especially useful for cutting thin materials, requiring no guide or template. Due to their ease of use and availability, scissors are an essential addition to your post-processing toolbox!
Manual post-processing tools
Scissors
Scissors are a versatile tool for freely cutting thin materials such as 1.5mm EVA or 1mm HIPS. They are especially useful for cutting thin materials, requiring no guide or template. Due to their ease of use and availability, scissors are an essential addition to your post-processing toolbox!
EVA 1.5mm, post- processed with scissors. Kevlar scissors
Kevlar scissors are designed for cutting harder and thicker materials that could damage regular scissors . They are particularly useful for cutting thicker, softer Mayku materials such as ultra-high molecular weight polymers. To cut parts made of UHMW, first use a band saw , then make a second cut with Kevlar scissors. Finally, smooth the edges with a file or sandpaper.
Kevlar scissors are designed for cutting harder and thicker materials that could damage regular scissors . They are particularly useful for cutting thicker, softer Mayku materials such as ultra-high molecular weight polymers. To cut parts made of UHMW, first use a band saw , then make a second cut with Kevlar scissors. Finally, smooth the edges with a file or sandpaper.
Cut a 3mm UHMW using Kevlar shears.
ultrasonic cutter
When handling tough materials such as PETG or PMMA, ultrasonic cutters can make the task much easier . For best results , it is recommended to use a powerful ultrasonic cutter with a longer blade . Mastering the technique of using this type of cutter may require some practice, as attention must be paid to the blade contact point and cutting angle to avoid dulling or melting the blade.
Because plastic fumes are emitted during this process, it is also crucial to wear protective equipment and operate in a well-ventilated area to ensure safety.
When handling tough materials such as PETG or PMMA, ultrasonic cutters can make the task much easier . For best results , it is recommended to use a powerful ultrasonic cutter with a longer blade . Mastering the technique of using this type of cutter may require some practice, as attention must be paid to the blade contact point and cutting angle to avoid dulling or melting the blade.
Because plastic fumes are emitted during this process, it is also crucial to wear protective equipment and operate in a well-ventilated area to ensure safety.
Cutting 4mm ABS with an ultrasonic cutter
Scalpel
If you need to cut thin materials such as 1.5 mm EVA or 1 mm HIPS, a scalpel can be a useful tool. They are particularly effective for achieving precise cuts and finishing.
If you need to cut thin materials such as 1.5 mm EVA or 1 mm HIPS, a scalpel can be a useful tool. They are particularly effective for achieving precise cuts and finishing.
Cut 1mm HIPS with a scalpel
Handheld rotary power tools ( Dremel)
Handheld rotary power tools like Dremel come with a variety of attachments to suit all situations, including cutting and machining parts. Cutting discs can be used to cut thin materials, while sandpaper attachments can remove excess material from thicker parts.
For example, ABS automotive parts are first post-processed using a band saw to remove excess material, and then machined and sanded with a Dremel to smooth the edges.
band saw
Band saws are essential tools for cutting rigid materials. They are a fast and reliable way to remove excess material and can be combined with more precise tools such as Dremel or ultrasonic cutters for even greater accuracy.
If you don't have space for a band saw , an electric jigsaw can be a great alternative , offering similar results and material compatibility . For example, when cutting ABS parts, you first use a band saw for two passes: one to remove excess material, and a second to get closer to the contour. Then, you grind the edges with a Dremel saw for a more consistent surface finish.
Band saws are essential tools for cutting rigid materials. They are a fast and reliable way to remove excess material and can be combined with more precise tools such as Dremel or ultrasonic cutters for even greater accuracy.
If you don't have space for a band saw , an electric jigsaw can be a great alternative , offering similar results and material compatibility . For example, when cutting ABS parts, you first use a band saw for two passes: one to remove excess material, and a second to get closer to the contour. Then, you grind the edges with a Dremel saw for a more consistent surface finish.
Use a band saw to remove excess material from the shaped parts.
Jig-assisted cutting
When post-processing thin parts (1-1.5mm), it is helpful to design and create a fixture to guide you during the cutting process. This fixture can be made using 3D printing or other techniques.
In the example below, you can see how to use a 3D printing jig (black) to cut a shaped part (white) with high precision.
When post-processing thin parts (1-1.5mm), it is helpful to design and create a fixture to guide you during the cutting process. This fixture can be made using 3D printing or other techniques.
In the example below, you can see how to use a 3D printing jig (black) to cut a shaped part (white) with high precision.
Manual post-processing example
The following are some post-processing procedures tested with different materials.
The following are some post-processing procedures tested with different materials.
HIPS
The HIPS sheet is 1 mm thick, making post-processing easy. After forming the blister packaging prototype, excess material is removed with Kevlar scissors , and then the edges are trimmed using 3D printing jigs and cutters to achieve a consistent finish.
The HIPS sheet is 1 mm thick, making post-processing easy. After forming the blister packaging prototype, excess material is removed with Kevlar scissors , and then the edges are trimmed using 3D printing jigs and cutters to achieve a consistent finish.
TIP: A band saw can be used as an alternative, but using Kevlar shears will not produce dust and does not require cleaning.
EVA
Due to the flexibility of EVA, small parts are extremely easy to demold, and parts can be easily cut using scissors, cutters, or scalpels.
If you are making a two- part mold using EVA, consider placing a sheet of paper underneath the mold as a base . This will create a permeable, flat layer and prevent the EVA from retaining the pitted patterns produced by the Mayku molding sheet .
EVA
Due to the flexibility of EVA, small parts are extremely easy to demold, and parts can be easily cut using scissors, cutters, or scalpels.
If you are making a two- part mold using EVA, consider placing a sheet of paper underneath the mold as a base . This will create a permeable, flat layer and prevent the EVA from retaining the pitted patterns produced by the Mayku molding sheet .
Two-part mold made using 1.5mm EVA on a Mayku Multiplier.
PMMA (polymethyl methacrylate)
PMMA possesses excellent mechanical and optical properties. For better precision, we recommend first cutting with a band saw , followed by ultrasonic cutting. Finishing is done using a Dremel tool with a sanding attachment, and hand sanding with high-grit sandpaper is also recommended for optimal results .
If you want the parts to be completely transparent, you will need to sand and polish the template before molding. To eliminate minor scratches, you can use a plastic polishing compound on the final part .
PMMA possesses excellent mechanical and optical properties. For better precision, we recommend first cutting with a band saw , followed by ultrasonic cutting. Finishing is done using a Dremel tool with a sanding attachment, and hand sanding with high-grit sandpaper is also recommended for optimal results .
If you want the parts to be completely transparent, you will need to sand and polish the template before molding. To eliminate minor scratches, you can use a plastic polishing compound on the final part .
Carlight components made of PMMA on the Mayku Multiplier
UHMW ( Ultra-High Polymer Materials )
Ultrapolymer materials are excellent non-friction materials, but that doesn't mean they can't be processed . We recommend using Kevlar shears , a band saw , or a scalpel to cut this material. Note that ultrasonic cutters are not very effective on this material. To finish the edges, you can sand them down or use a scalpel and clamps for cutting.
Ultrapolymer materials are excellent non-friction materials, but that doesn't mean they can't be processed . We recommend using Kevlar shears , a band saw , or a scalpel to cut this material. Note that ultrasonic cutters are not very effective on this material. To finish the edges, you can sand them down or use a scalpel and clamps for cutting.
UHMW's protective equipment prototype made using Mayku Multiplier
ABS
4mm ABS can be post-processed using many of the tools mentioned in this guide. While excess material can also be processed automatically using CNC or other methods , it is best to remove it using a band saw or ultrasonic cutter.
For finishing, we recommend using Dremel or hand sanding, and trimming with a scalpel.
4mm ABS can be post-processed using many of the tools mentioned in this guide. While excess material can also be processed automatically using CNC or other methods , it is best to remove it using a band saw or ultrasonic cutter.
For finishing, we recommend using Dremel or hand sanding, and trimming with a scalpel.
ABS uses automotive parts manufactured by Mayku Multiplier.
Post-processing memo
In the table below , you can see the compatibility between some materials and the different post-processing tools described in this guide.
In the table below , you can see the compatibility between some materials and the different post-processing tools described in this guide.
Has this detailed introduction helped you better understand manual post-processing of thermoformed parts? If you need more details, please feel free to contact us !
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SanDiMa offers more than just 3D printing ; we provide three major OEM services: " 3D Printing Manufacturing ," " 3D Scanning Services ," and " Spatial 3D Scanning Services "!
Follow our fan page and stay up-to-date with the latest news:
Facebook: https://www.facebook.com/3dmart.com.tw/
Instagram: https://www.instagram.com/3dmart
LinkedIn: https://www.linkedin.com/company/3dmart/
References