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Home» Education» Filament Tutorials»Thermoform Your 3D Printed Parts! Read Now!
Thermoform Your 3D Printed Parts!  Read Now!

Thermoform Your 3D Printed Parts! Read Now!

Andrew Delisle 17 Mar 2018 Filament Tutorials 74 Comments 5514 Views

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Table of Contents

  • Introduction to Thermoform
  • Methods to Thermoform
  • Safety First
  • The Heat Gun Method
  • Hot Water Bath Method
  • But… Why?
  • E-Nable Applications
  • The Draw Backs
  • Conclusion

Introduction to Thermoform

Hey guys and gals, today I am going to go over how to thermoform your 3D printed parts.  This is useful for the 3D printed hands and arms that I do for E-Nable.  I will go over some of the benefits to this process, and some ways that you can use it in your designs and prints.

Thermoforming is the process of heating your 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.

All of these parts you are about to see where printed 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.

Methods to Thermoform

There are a few different methods to thermoform your prints.  The two main 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 whole part to a stable temperature without the risk of melting it.  This method also typically requires nothing extra to be purchased.  There are still many houses without a heat gun, come on people. It was in 2018.  Kidding!

Safety First

Thermoform Your 3D Printed Parts!  Read Now!
Don’t let this be your house!!!.

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!

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. 

Move the heat gun quickly either left/right or up/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 tends to go from nothing… to a hot drippy print quickly… so be prepared. Once the print is heated, bend it any way that you would like.  When the plastic cools, it will retain the shape that you manipulated it to.

Hot Water Bath Method

The hot water bath method requires you to submerge the part into boiling water until it becomes pliable.  This is, in my opinion, the superior way to thermoform as opposed to the heat gun. This method allows the whole part to get to the same temperature.  The water doesn’t need to be boiling, but it should be able to get around 200F/90c.

Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!

You can use a pot on the stove, hot water from a tea 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 as to not 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?

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 parts.  Buckle up and prepare to be amazed!

Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!
Thermoform Your 3D Printed Parts!  Read Now!

E-Nable Applications

The forearm gauntlet and bicep cuff that I print for the E-Nable 3D printed hands now print 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 meant to be worn on your arm. The thermoformed gauntlets print faster than the old style because they require no support structure. This saves you money on printer operation and the filament.  The thermoformed gauntlets are also much stronger than the old style.

Thermoform Your 3D Printed Parts!  Read Now!
old style gauntlet, Layer lines running through the pin hole
Thermoform Your 3D Printed Parts!  Read Now!

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! 

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.  

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

3d printed 3d printed hand 3d printed prosthetics 3d printer 3d printing 3d printing processing e-nable heat gun nub werkes nubwerkes prosthetic hand thermo-form thermo-formed thermo-forming thermoform thermoformed thermoforming 2018-03-17
Tags 3d printed 3d printed hand 3d printed prosthetics 3d printer 3d printing 3d printing processing e-nable heat gun nub werkes nubwerkes prosthetic hand thermo-form thermo-formed thermo-forming thermoform thermoformed thermoforming
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Authors

Posted by : Andrew Delisle
I'm a father of four, happily married, IT professional with nearly 15 years in the field. I live in Michigan and have been 3D printing since
Previous Article :

Who is Nub Werkes? 3D Printed Hand Time

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74 Comments

  1. william
    March 17, 20184:26 pm -

    great work andrew keep the articles comeing

    Reply
  2. Ross Sage
    May 26, 201810:24 pm -

    Very interesting concept

    Reply
  3. Tony
    May 27, 20188:17 am -

    Interesting. I will have to give this a go 🙂

    Reply
  4. JC
    May 28, 20186:34 pm -

    Really interesting technique! Will have to give it a try

    Reply
  5. Anne
    May 29, 20181:14 pm -

    This is such fascinating technology! Would love to try it out

    Reply
  6. Alberto
    May 29, 20181:53 pm -

    I have to try it

    Reply
  7. Calvin
    May 29, 20183:57 pm -

    Really complex neat new tech! Love what it can do

    Reply
  8. Mathew W
    May 29, 20185:47 pm -

    3D printing is going to take the world by storm sooner than later.

    Reply
  9. Leanne
    May 30, 20182:09 am -

    I definitely learned something new (never heard of thermoforming). Also thank you for your donations and helping people in need .

    Reply
  10. Denis M.
    May 30, 20184:44 am -

    Wow, very interesting. Thanks for this, will be useful in the future.

    Reply
  11. Laurence Price
    May 30, 20184:53 pm -

    Great contest, awesome prize, thanks for the chance to win!

    Reply
  12. Denis M.
    June 2, 20181:57 am -

    Thanks!

    Reply
  13. Robert Price
    June 6, 20188:11 am -

    Very interesting

    Reply
  14. Stevie
    June 6, 201811:47 am -

    I think The hot water bath method is easiest.

    Reply
  15. Doug Matheson
    June 8, 20186:15 pm -

    Looks awesome

    Reply
  16. John Hubbard
    June 8, 20188:00 pm -

    Looks cool

    Reply
  17. Leanne
    June 8, 201810:37 pm -

    The 3d printing technology is just amazing . I would love to see it in person .

    Reply
  18. Kim Styles
    June 9, 20181:24 pm -

    i am very impressed with this although I would be using the hot water bath method I think!

    Reply
  19. Leanne
    June 10, 20181:11 pm -

    3d printing technology sure is fascinating. Can’t wait to see what they can do with 3d printers in a few years .

    Reply
  20. Leanne
    June 11, 20184:28 pm -

    Would love to try 3d printing . It’s is just amazing .

    Reply
  21. Justin Flugum
    June 11, 201811:00 pm -

    I had no idea forming 3d prints was a thing.

    Reply
  22. Chemy Torres
    June 12, 20182:04 am -

    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.

    Reply
  23. Kim Styles
    June 12, 20183:44 pm -

    This really fascinates me – It would be great for using for making drawing models

    Reply
  24. Leanne
    June 12, 201810:07 pm -

    3d printing is very fascinated. I would love the learn how to use a 3d printer .

    Reply
  25. Aftertell
    June 13, 201812:58 am -

    Coolio

    Reply
  26. Cole
    June 13, 20182:10 am -

    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.

    Reply
  27. Chemy
    June 13, 20183:38 am -

    Again reading it, as many said, interesting technique.

    Reply
  28. Chemy
    June 13, 20183:39 am -

    As many said, interesting technique, I see the practical uses of it.

    Reply
  29. Chemy Torres
    June 13, 20183:40 am -

    My comments doesn’t show today, but good article. last attempt

    Reply
  30. Greg
    June 13, 20185:39 pm -

    looks interesting!

    Reply
  31. Leanne
    June 13, 20189:40 pm -

    Great article and info . Would love to learn more about how the 3d printing technology works. It’s very interesting

    Reply
  32. Chemy Torres
    June 14, 20183:25 am -

    Amazing, already read it a couple of times.

    Reply
  33. Daniel
    June 14, 20185:35 am -

    cool

    Reply
  34. Ian Edwards
    June 14, 201810:22 am -

    Very cool, nice to know for next time I am doing to same

    Reply
  35. Kim Styles
    June 14, 201812:24 pm -

    I am sure your work has helped many

    Reply
  36. Leanne
    June 14, 201811:10 pm -

    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.

    Reply
  37. Kim Styles
    June 15, 201812:44 pm -

    I think this would helped with forming prototypes for metal work and sculpture

    Reply
  38. Arve Bjørnerud
    June 15, 20182:22 pm -

    Cool

    Reply
  39. Leanne
    June 15, 20189:59 pm -

    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 .

    Reply
  40. Kim Styles
    June 16, 20189:34 am -

    E-Nable looks such a great cause – there are so many war injuries in so many countries

    Reply
  41. Leanne
    June 16, 20183:12 pm -

    A very good cause you support . I love how many people this technology is helping , it’s pretty amazing .

    Reply
  42. Kim Styles
    June 17, 201810:26 am -

    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

    Reply
  43. Thomas mclind
    June 17, 201811:05 am -

    Wow!

    Reply
  44. okuma
    June 17, 201812:16 pm -

    I really hate support material, I’ll have to try this!

    Reply
  45. Kyle
    June 17, 20185:03 pm -

    Never thought about doing this

    Reply
  46. Andrew Delisle
    June 17, 20187:01 pm -

    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!

    Reply
  47. Chemy Torres
    June 17, 201811:10 pm -

    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

    Reply
  48. Joseph
    June 18, 20187:30 am -

    I’m just here to enter the contest

    Reply
  49. Kim Styles
    June 18, 20185:30 pm -

    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

    Reply
  50. Leanne
    June 18, 201810:12 pm -

    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 .

    Reply
  51. Leanne
    June 19, 201810:43 pm -

    Awesome technology. Would love to learn how to use a 3d printer .

    Reply
  52. Kim Styles
    June 20, 20188:47 am -

    Technology for artificial limbs has advanced rapidly in the last two decades thank goodness, and products like this are incredible

    Reply
  53. James McCann
    June 20, 20186:53 pm -

    Major Cool!

    Reply
  54. Leanne
    June 20, 201811:44 pm -

    Awesome technology . So many uses for 3d printing , can’t believe they are 3d printing houses nowadays.

    Reply
  55. Chemy Torres
    June 21, 20184:15 am -

    Nice article

    Reply
  56. Kim Styles
    June 21, 20189:15 am -

    I think for what this incredible printer does it is really reasonably priced !

    Reply
  57. Bob Marl
    June 21, 201811:28 pm -

    A few years ago 3D printing was only for the professionals, thank God such models have come out for the public.

    Reply
  58. Chemy Torres
    June 22, 20182:46 am -

    Great article, useful technique.

    Reply
  59. Kim Styles
    June 22, 20189:06 am -

    I think this should l be in art courses in colleges etc as it is not just a science but an art

    Reply
  60. Leanne
    June 22, 201810:10 pm -

    Awesome technology. Can’t wait to see what they can do with it in the future .

    Reply
  61. Chemy Torres
    June 23, 20185:22 am -

    Something I forgot to mention, it’s too nice from you that you donate, that’s simply wonderful.

    Reply
  62. Kim Styles
    June 23, 20186:47 am -

    Thank you for the informative introduction to Thermoform

    Reply
  63. Dunfy
    June 23, 20188:59 am -

    Very dope!!! What a time to be alive lol

    Reply
  64. paula cheadle
    June 24, 201812:08 am -

    would love to try 3D printing, it looks awesome

    Reply
  65. PHILIP TAYLOR
    June 24, 20189:24 am -

    Thank you for the great video

    Reply
  66. Kim Styles
    June 24, 201810:29 am -

    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

    Reply
  67. Chemy Torres
    June 24, 201811:21 am -

    Nice article, 😉

    Reply
  68. Leanne
    June 24, 20182:04 pm -

    Awesome article . This technology is so interesting. I would love to learn more about it .

    Reply
  69. James Nattrass
    June 24, 20182:26 pm -

    Thanks for this, I’m going to test this method in the future

    Reply
  70. Chemy Torres
    June 24, 20182:55 pm -

    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.

    Reply
  71. Max
    February 20, 201911:32 pm -

    Couldn’t get the cura profile just directs to 404 page

    Reply
    • Andrew Delisle
      February 21, 20194:14 am -

      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.

      Reply
  72. admin
    June 28, 201912:27 am -

    Thank for all the lovely comments, has anyone done this process yet?

    Reply
  73. Kennet McCoy
    July 6, 20198:17 pm -

    This is a great idea. Love the option of a Hot Water Bath
    Well done

    Reply

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