Take template creation to a new level.
High-quality stencils mean the difference between success and failure in thermoforming. This means you should have the knowledge of best practices in thermoforming when designing and creating stencils. Below, we'll show you how to create high-quality thermoforming stencils using SLS 3D printing technology !
What is curing?
Thermoforming is a popular manufacturing process that involves heating a sheet of plastic and shaping it around a mold to create a specific shape. A key step in thermoforming is creating a template for shaping the plastic sheet.
Before we begin, let's understand what SLS 3D printing is!
Laser powder sintering (SLS) is a 3D printing technology belonging to the powder bed melting family of additive manufacturing processes . It uses a high-power laser to fuse small particles of plastic powder together. Unlike other 3D printing technologies, SLS does not require any support structure because the powder itself is the support structure. The material used in SLS powder sintering is a particulate thermoplastic polymer, which offers very high design freedom, high precision, and produces parts with good and consistent mechanical properties.
SLS 3D printing workflow
Through the videos and brief introductions above, you should now have a basic understanding. So, what are the benefits of using SLS 3D printing? Below are some advantages of SLS 3D printing , particularly related to thermoforming template creation :
Internal porosity provides higher quality.
One of the main advantages of using SLS 3D printing technology for thermoforming is the porous nature of the produced parts. What are the benefits of this? Porosity means that there's no need to add pores to the stencil, or the number of pores required is significantly reduced. This is crucial for thermoforming stencils , as pores can cause the plastic sheet to bubble and deform during the molding process . Therefore, reducing pores results in higher quality prints, increased product stability, and faster production!
Highly advantageous material properties
SLS 3D printing typically uses nylon, a material with excellent mechanical properties and temperature resistance. This makes it an ideal material for making thermoforming templates.
Skilled at making complex parts
SLS 3D printing technology excels at creating complex parts because the laser during printing illuminates every corner, resulting in a high level of detail. Furthermore, SLS 3D printing requires no support material; the powder itself acts as a support, eliminating the need for other materials . This allows for greater design flexibility and the creation of more complex parts.
Having introduced SLS 3D printing and its benefits, let's now formally explain the workflow and precautions for creating content using it.
Design and manufacture of thermoforming templates
Here are some tips to keep in mind when creating thermoforming templates using SLS 3D printing :
Part orientation
When designing thermoforming templates for SLS 3D printing , the orientation of the part on the build platform must be considered. This is because the temperature of the powder varies depending on the position of the part, which can lead to warping.
If your stencil is wide and relatively flat, it is recommended to 3D print at a small angle of 20º to minimize warping.
Post-treatment and surface finish
While SLS 3D printing is an excellent technology for manufacturing complex shapes and pore-free parts, its drawback is that the resulting parts often have a rough surface. This is where media jetting comes in. It is strongly recommended to use media jetting* to thoroughly remove powder from SLS parts to achieve a smoother surface finish.
*Media spraying is a process for cleaning and preparing surfaces for various repair, restoration, or coating applications. It involves propelling abrasive materials onto the surface at high speed.
Furthermore, the template can be polished or coated to achieve different surface effects, providing more personalized options. However, it is important to note that altering the template surface may affect its porosity, thereby impacting the final result of the thermoforming process.
Recommended SLS materials for thermoforming
Nylon 12 is the most commonly used SLS 3D printing material and an ideal material for making thermoforming stencils. This is because it has excellent mechanical properties and temperature resistance. Nylon 12 has a heat deflection temperature of 171ºC (0.45 MPa) and an ultimate tensile strength of 50 MPa. Furthermore, parts made from this material are porous, eliminating the need for or reducing the number of openings in the stencil, making it more convenient!
Applications of SLS thermoforming templates
SLS 3D printing offers several advantages in thermoforming applications due to the unique characteristics of its parts:
• End parts: SLS templates offer excellent strength and temperature resistance, while also achieving high dimensional accuracy. Therefore, they are ideal for manufacturing high-quality end parts.
• Small-batch production: SLS stencils typically have a longer lifespan than stencils produced by other 3D printing technologies, making them the best choice for creating stencils that can be used multiple times in small-batch production.
• Complex geometries: Due to the high precision of lasers and the ability to use powder as its own support material, SLS 3D printing technology can create thermoforming templates with complex geometries.
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