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How to Thermoform 3D printed parts in 2022. This is useful for the 3D printed hands and arms that I do for E-Nable. I will go over some benefits to this process, and some ways that you can use it in your designs and 3D prints. Thermoforming is the process of heating your 3D prints after they are finished printing and then reshaping them. This allows you to create more complex shapes and designs that would typically be possible. Also, let me say… I have only used this process with PLA and was not able to Thermoform Nylon in a hot water bath. I printed these parts you are about to see on my venerable Tevo Black Widow. It’s equipped with TMC2100 stepper drivers on the X/Y axis, parts cooling fan, Volcano hotend with Micro Swiss goodies, and a glass bed.
Thermoform 3D Printed Parts
There are a few different methods to thermoform your prints. The two primary methods are a hot water bath or a heat gun. I prefer the hot water bath. I feel it is an excellent way to get the entire part to a stable temperature without the risk of melting it. This method also typically requires nothing extra to be purchased.
Thermoform Safety First
With that said, these instructions are to be taken at your own risk. Please be safe, as there is a high chance of getting burned. If you intend to try this out, please read these instructions a few times. Be familiar with the process so that you can give it your full attention. After all that… let’s start to thermoform!
Don’t let this be your house!!!.
The Heat Gun Method
The heat gun Thermoform method requires finding a safe space to heat your 3D printed part without the fear of burning your dwelling to the ground. Find a scrap plate, dish or pan that is NOT FLAMMABLE. That part in ‘caps’ is pretty important. I will not be held responsible for any structure fires in the name of 3D printing. Keep the heat and blower speed on the heat gun low and also keep the gun 6-8″ away from your 3D printed parts.
Flash the heat gun quickly either left to right or up and down, depending on the overall shape of the 3D printed part. Do not keep the heat gun focused on one place for too long. This Thermoforming method goes from nothing… to a hot drippy print quickly… so be prepared. Once the print is heated, bend it in any shape or form that you would like. When the plastic cools, it will keep the shape that you manipulated it to.
Hot Water Bath Method
The hot water bath method requires you to submerge the 3D part into boiling water until it becomes pliable. This is the superior way to Thermoform as opposed to the heat gun. This method allows the entire model to get to the same temperature all around. The water doesn’t need to be boiling, but it should be able to get around 200F/90c.
You can use a pot on the stove, hot water from a kettle into a dish, or even use an electric skillet as I do. The skillet allows me to submerge large parts fully and can heat the water fairly quickly.
After getting the water up to temperature, submerge your part until it becomes pliable. Remove the region from the water with some tongs and cool for a few seconds so you don’t burn your hands. Once it’s cold enough for you to touch, form it to your heart’s delight safely. If you didn’t get it correct the first time, toss it back in the water, and it will go back to its original shape. Pretty handy, huh?
But Why Not Just 3D Print The Shape You Want?
So you are probably wondering why go through all this hassle? Why not print the shape I wanted to begin with? Well, what if I told you that this would save you time, money, and filament.. while also strengthening your 3D printed parts? Buckle up and prepare to be amazed!
E-Nable 3D Printed Hands
The forearm gauntlet and bicep cuff I printed for the E-Nable hands are now printed entirely flat. This wasn’t always the case. Some models printed the forearm gauntlet vertically while some printed along the X or the Y-axis. The problem with this is that the holes for the wrist and elbow pins are set along a layer line. This makes the design prone to breaking and cracking.
The old style gauntlets also suffer from being ill-fitting and less forgiving to flexion. Which are all terrible compromises for something that is worn on your arm. The Thermoformed gauntlets print faster than the old style because they require no support structure. This saves your money on 3D printer operation and the filament. The Thermoformed gauntlets are also much stronger than the old style.
Instead of the pin holes being on a layer line, they go all the way through the layers. This reduces the possibility of cracking during use and improves flexion in the parts. Using the thermoform gauntlets also promotes a better fit for the recipient.
If your measurements weren’t quite right, you now can quickly reheat the part and adjust it for a better fit. You can use the thermoform principles in parts design. Was the design that you were initially working on too challenging to print? Try adjusting it for thermoform!
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- old style gauntlet, Layer lines running through the pin hole
The Draw Backs
The only downside to this design method is that parts are not ready directly from the print bed; they require post-processing with either of the techniques that I described above. I’ve also noticed that too hot of temperatures can affect the 3D printed parts colour and finish. It would be best to try this on a scrap piece before you dedicate an essential print job to this.
Thermoform 3D Printed Parts Conclusion
So, today you’ve learned what Thermoforming is, what it’s suitable for, and some of its drawbacks. It’s up to you to either wipe your brain of the last 5-10 minutes or thermoform a 3D printed part right now.
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great work andrew keep the articles comeing
Very interesting concept
Interesting. I will have to give this a go 🙂
Really interesting technique! Will have to give it a try
This is such fascinating technology! Would love to try it out
I have to try it
Really complex neat new tech! Love what it can do
3D printing is going to take the world by storm sooner than later.
I definitely learned something new (never heard of thermoforming). Also thank you for your donations and helping people in need .
Wow, very interesting. Thanks for this, will be useful in the future.
Great contest, awesome prize, thanks for the chance to win!
Thanks!
Very interesting
I think The hot water bath method is easiest.
Looks awesome
Looks cool
The 3d printing technology is just amazing . I would love to see it in person .
i am very impressed with this although I would be using the hot water bath method I think!
3d printing technology sure is fascinating. Can’t wait to see what they can do with 3d printers in a few years .
Would love to try 3d printing . It’s is just amazing .
I had no idea forming 3d prints was a thing.
Well adding this is a great option, I’m pretty sure other materials can be used this way, for printing faster and to giving some on the road form.
This really fascinates me – It would be great for using for making drawing models
3d printing is very fascinated. I would love the learn how to use a 3d printer .
Coolio
I imagine this is a useful process for creating stronger, more durable prosthetic limbs. I’m curious if this process would be useful in 3D-printed firearms making as well.
Again reading it, as many said, interesting technique.
As many said, interesting technique, I see the practical uses of it.
My comments doesn’t show today, but good article. last attempt
looks interesting!
Great article and info . Would love to learn more about how the 3d printing technology works. It’s very interesting
Amazing, already read it a couple of times.
cool
Very cool, nice to know for next time I am doing to same
I am sure your work has helped many
Awesome article . This technology is so intriguing, I would love to try it or even just see how it works . Amazing what they are doing with 3d printers recently.
I think this would helped with forming prototypes for metal work and sculpture
Cool
What an incredible technology. Can’t believe some of the things they are making with 3d printers . Would love to learn how to use one .
E-Nable looks such a great cause – there are so many war injuries in so many countries
A very good cause you support . I love how many people this technology is helping , it’s pretty amazing .
I like the way if you get it wrong the first time you can put it back in the water and it goes back into its original shape. as a newbie I think I would be doing this quite a lot to start with, its such an amazing product I can see so many possibilities for me
Wow!
I really hate support material, I’ll have to try this!
Never thought about doing this
Thanks for all the responses guys. Also, your comments won’t show right away as we have to approve them all individually. This helps us keep spam at bay. Thanks again guys and keep the comments flowing! If you need help or have an improvement.. let me know!
Again nice article, there is another good reason, to convine two materials, for example if you need to add internal parts which might be very hard or imposible to do if the printed piece is already in the final shape
I’m just here to enter the contest
The whole thing is fascinating – I have been looking at 3D printing as whole now as a possibility of a real hobby or, if I get the hang of it, a small business . I am astounded by what can be created
I am so impressed with how many things can be made from 3D printing . It’s amazing , I would love to learn how to use a 3d printer .
Awesome technology. Would love to learn how to use a 3d printer .
Technology for artificial limbs has advanced rapidly in the last two decades thank goodness, and products like this are incredible
Major Cool!
Awesome technology . So many uses for 3d printing , can’t believe they are 3d printing houses nowadays.
Nice article
I think for what this incredible printer does it is really reasonably priced !
A few years ago 3D printing was only for the professionals, thank God such models have come out for the public.
Great article, useful technique.
I think this should l be in art courses in colleges etc as it is not just a science but an art
Awesome technology. Can’t wait to see what they can do with it in the future .
Something I forgot to mention, it’s too nice from you that you donate, that’s simply wonderful.
Thank you for the informative introduction to Thermoform
Very dope!!! What a time to be alive lol
would love to try 3D printing, it looks awesome
Thank you for the great video
this is a great prize and very generous. I would love to share this with my son who is very artistic and great with technology
Nice article, 😉
Awesome article . This technology is so interesting. I would love to learn more about it .
Thanks for this, I’m going to test this method in the future
I don’t know if you did it intentionally but each time I come here I see something I missed the moment before.
As I said great technique, great article.
Couldn’t get the cura profile just directs to 404 page
Max, We are in the process of moving things around on the co.uk server. I can email you the profile tomorrow. This is for the older version of Cura. Cura 15.0.6, let me know if you still want it.
Thank for all the lovely comments, has anyone done this process yet?
This is a great idea. Love the option of a Hot Water Bath
Well done