1. THERMOFORMING: ADVANCED TOOLING OPTIONS
Michael Mabie
Senior Applications Engineer
Stratasys, Inc.

2. Thermoforming Simple, inexpensive process Wide range of industries
w Aerospace w Electronics
w Packaging  Medical
Broad application range
Low-volume and high-volume
Small and large parts
Photo: Courtesy of NASA

3. Thermoforming Process

4. Thermoforming Process

5. Thermoforming Opportunity
Traditional tooling
Can be expensive
Can be time consuming
Vent holes
Tedious
Labor intensive
Photo: Courtesy of Flickr KP Choo

6. FORTUS for Thermoforming
Alternative tool making process
Reduces labor
Reduces lead time
Reduces cost
FDM® process
Industry leading
Production-grade thermoplastics
Extruded, deposited in layers

7. FDM Process

8. Applying Fortus Key items Benefits Additive process Materials
Build controls
Benefits
Simple 5 step process
Materials for speed/tool life
Process controls

9. Application Brief 50% 86% 29% 75% Consumer packaging CURRENT FORTUS
SAVINGS
Lead Time
3 days
1.5 days
50%
Labor Time
14 hours
2 hours
86%
Total Cost
$700
$500
29%
Story:
Machined tooling: prototype only so easy to machine material. But 1 man-day to drill vent holes (1 – 2 thousand for the multi-cavity tool)
FDM: simple in and out
Stress the labor savings. For some, reduction in labor is much more important that lead time (e.g. not enough people to get the job done). Also the reduction is much more impressive.
labor rate $35 for Current method and $62 for FDM. Assumed more highly skilled labor for machine ops, etc.
Note that the labor line (indented) represents the labor portion of the total listed in the row above.
The story
Time and money not biggest value. Process change was. Could be prototyping vacuum forming tool while part still being designed. Off the critical path!
Also, maybe, add another embellishment….after prototyping, vapor smooth and prick surface to come up with beautiful marketing samples. (story from our most recent vapor smoothing guided)
Labor Cost
$490
$125
75%

10. Fortus Process Design mold Process in Insight™ Select FDM material
Apply larger air gaps
Apply sparse fill style

11. Fortus Process Manufacture mold Prep mold Mount mold
Start thermoforming

12. Application Brief 75% Aerospace (defense) 93% Engine cowling 44%
Photo: Courtesy of NASA
CURRENT
FORTUS
SAVINGS
Lead Time
10 days
2.5 days
75%
Labor Time
30 hours
2 hours
93%
Total Cost
$2,700
$1,500
44%
Photo: Courtesy of Flickr srharris

13. Return on Investment 62% 36% CLIENT 1 CLIENT2 SAVINGS Lead Time 50%
75%
62%
Labor Time
29%
44%
36%

14. When to use FORTUS Prototype package design Low-volume production
Bridge-to-tooling

15. Summary Thermoforming tooling option Reduces Little process change
Time
Labor
Expense
Little process change

16. More Information Test it, Prove it. Download Application Guide
Send file for benchmark
Download Application Guide
Request Consultation
Michael Mabie, Senior Applications Engineer
Tel