manufacturing of thermoformed mould from 3d printing
Spanish company leader in the production of packaging for containers and blister packs, it carries out thermoforming processes for the manufacture of its products in different formats and materials.
The company designs different types of trays in different sizes and sizes to be able to carry out its business, requires the various die-cutting companies to mechanize the moulds of the products adapted to the initial drawings, which are usually made of aluminum. Once the mould is received, the company carries out a thermoforming process with PET sheets of different thicknesses for the final manufacture of the product.
• Production costs of the moulds. High investment costs due to different sizes and shapes.
• Long waiting time until receipt of the mold from order launch.
• High investment costs if a client wants a prototype of special measures before submitting a formal order.
• High depreciation costs of the mould for small series.
PHASES OF THE SOLUTION PROPOSAL
• Use 3D printing technology with the JCR 1000 large format 3D printer for making moulds, obtaining:
– Reduction of unit costs, as this technique is more competitive than the processing systems used for the production of moulds and raw materials.
– Reduction of mold waiting time by more than 50%.
– Elimination of investments in moulds.
– Possibility to realize functional prototypes at very low costs.
• Modeling and making a mould on various commercial 3D printing materials with the Sicnova JCR 1000 3D printer.
RESEARCH AND THE DEVELOPMENT OF THE CASE
The product research and development team carried out the design and development of a material by means of FFF in any type of printer with the following properties:
• Excellent adhesion to the base.
• No contractions, eliminating deformations.
• Material with sufficient mechanical rigidity to withstand the pressures and impacts of the thermoforming process.
• Perfectly stable up to 100ºC.
Note: It is preferable to drill air evacuation holes using post drilling processes after the 3D impression of the mold.
IMPACT ON THE CUSTOMER
• 100% savings on investment in moulds.
• Possibility to offer the customer functional samples at very low costs (without investment impact).
•Possibility of creating functional prototypes of finished products with a 99% reduction in costs compared to the conventional process.
• Possibility of making small pre-series or lots at very low costs.