User manual

Z406 System User Manual Z Corporation
www.zcorp-users.com 65
6.8 THERMOFORMING
This process consists of heating a thermoplastic sheet to a formable plastic state and then applying
air pressure and/or mechanical assists to shape it to the contours of a mold. In this process, the air
pressure may range from almost zero to several hundred psi. ‘Vacuum forming’ is the term given
when a pressure differential of up to approximately 14 psi (atmospheric pressure) is used. The
pressure is obtained by evacuating the space between the sheet and the mold in order to utilize this
atmospheric pressure. Vacuum forming will give satisfactory reproduction of the mold configuration
in the majority of forming applications. Manufacturers can use all types of thermoplastic materials –
PVC, polystyrenes, polyesters, acrylics etc. in this process.
Making light gauge (plastic less than 0.060”) thermoforming molds for prototype parts is an ideal use
for Z Corporation 3D Printers and plaster powder.
For more information regarding the process and the industry, check out SPI’s website:
www.plasticsindustry.org/index.htm
where you can search SPI's Membership Directory & Buyer's
Guide for thermoformers.
In the example below, the industrial designer wanted to get a feel of his design in the actual material.
He was able to generate a mold and produce a sample in a period of days.
MOLD PROTOTYPE
The packaging company that produced the prototypes below uses the parts to generate samples for
their sales department, who then use them to collect customer feedback.