Thermoforming with FDM Rapid Prototype tooling
Thermoforming with FDM Rapid Prototype tooling
(OP)
I am looking to have a thermoformed catheter tray made. The tray is 40" long 5" wide. The material is HIPS.
I need about 150 trays and then I know the design is going to change. I really don't want to invest much in tooling, so FDM tooling seems like a good option in theory. I have been told though that they only generally get 10 parts out of the tools. I haven't had a good explanation of why the tools fail.
The RedEye website makes FDM tooling sound great. http:/ /www.redey eondemand. com/APP_FD M_Thermofo rming.aspx
It sounds like everyone is using ABS, when polysulfone might be a better option. I am looking for some advice on making low volume reasonably large thermoformed parts. What are the limitations of FDM tooling?
I need about 150 trays and then I know the design is going to change. I really don't want to invest much in tooling, so FDM tooling seems like a good option in theory. I have been told though that they only generally get 10 parts out of the tools. I haven't had a good explanation of why the tools fail.
The RedEye website makes FDM tooling sound great. http:/
It sounds like everyone is using ABS, when polysulfone might be a better option. I am looking for some advice on making low volume reasonably large thermoformed parts. What are the limitations of FDM tooling?






RE: Thermoforming with FDM Rapid Prototype tooling
I talked to my vendor about this a while back and seemed they'd only just started to look at using rapid manufactured tools.
On the tool failing I'd guess is was from the thermal cycling.
I'll be interested to see what others say as the volumes they claim for this tooling on redeye is in our ball park.
Your part is on the large side for making the tool in one place by FDM, you may have to make it in 2 parts and join together which may be a weak point.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Thermoforming with FDM Rapid Prototype tooling
If it is ABS, heat will be the thing that kills it. Cooling between cycles might help for low volume.
It should also be possible to cast a mould in epoxy or thermoset polyester using the FDM model as a plug. If this was incorporated in the original plan, the FDM could be sized to correct for mould shrinkage that occurs when making the mould.
If it's a simple part it might be just as easy to fabricate it out of wood and forget about high tech.
Polysulphone will make a substantially stronger prototype.
There was some time ago a rapid prototype technique that UV cured epoxies. SLA or stereo lithology I think.I think.
Regards
Pat
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RE: Thermoforming with FDM Rapid Prototype tooling
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Thermoforming with FDM Rapid Prototype tooling
I agree FDM usually can offer materials more in keeping with the material to be used for the final product.
Regards
Pat
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RE: Thermoforming with FDM Rapid Prototype tooling
I was really hoping that vendors would know more about rapid prototyping approaches to tooling. Or at least give me an understanding of when it is appropriate.
The mold would definitely have to be two pieces as the largest build size is 24" I believe.
$4000-$5000 for a tool I am going to scrap after 150 pieces is expensive for packaging.
RE: Thermoforming with FDM Rapid Prototype tooling
I had one thermo form vendor that was quoting Al tooling in the price range you're talking about (assuming US $) for parts in your size range.
Some might be able to splash a wooden mold with epoxy or similar for the volumes you're talking about for less money.
(Pat, 'higher grade' was perhaps a poor choice of phrase, sorry. More robust or/tougher or production representative may have better.)
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Thermoforming with FDM Rapid Prototype tooling
The surface finish of the FDM model will show up in the parts. A machined part will give you a better finish.
The nice thing about FDM molds is that they are porous and you don't have to drill holes.
RE: Thermoforming with FDM Rapid Prototype tooling
My most recent experience they only lasted about 5 units before showing serious damage.
That said, they were layered MDF, not real wood, so maybe the adhesive in the MDF was more prone to damage.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Thermoforming with FDM Rapid Prototype tooling
RE: Thermoforming with FDM Rapid Prototype tooling
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Thermoforming with FDM Rapid Prototype tooling
RE: Thermoforming with FDM Rapid Prototype tooling
Regards
Pat
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RE: Thermoforming with FDM Rapid Prototype tooling
Freeman sells lots of grades of hard and soft wood for tooling as well as foams. They even sell giant pieces of MDF that don't have to be layered. The life also depends on the geometry of the tool.
RE: Thermoforming with FDM Rapid Prototype tooling
Regards
Pat
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