Large format thermoforming molds with 3D pellet printing - Duo Form

Cost reduction, optimized production time and digital innovation with EXT Titan Pellet printers.

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Duo Form optimizes thermoforming with 3D pellet printing

Thermoforming is an ever-evolving industry, and Duo Form, a leading manufacturer of thermoformed components, has adopted 3D pellet extrusion printing to speed up production time and reduce costs. Thanks to the printers Titan EXT Pellet from 3D Systems, Duo Form has revolutionized the mold making process, improving its competitiveness and operational efficiency.

 

 

Reducing time and costs in mold production

In the thermoforming industry, traditional CNC processes for making metal or ceramic molds involve high costs and long lead times.

The adoption of large-format 3D printing has enabled Duo Form to replace traditional molds by achieving the following advantages:

  • 1

    Reduce material costs by up to 10 times

    Through the use of plastic pellets instead of filaments or CNC mold materials

  • 2

    Accelerating production

    With a printing speed up to 10 times faster than filament printing

  • 3

    Eliminate the need for special equipment

    Due to the possibility of integrating features for vacuum creation directly into the molded parts

The solution: TITAN Ext Pellet

TITAN EXT 800 Pellet is the industrial 3D printer with the largest print area and lowest production cost: this allows parts to be produced at a low cost per part.
The Titan EXT 800 printer is ideal for the production of medium to large parts, applications such as production equipment, models but also end-use parts. It is extremely fast: up to 10 times faster than filament printers.TITAN EXT printers have a wide range of printing materials, including loaded and flexible materials.

Thanks to EXT Titan Pellet technology, Duo Form can now make durable, high-precision thermoforming molds with innovative materials such as, for example, glass-filled polycarbonate, ensuring durability, thermal resistance and superior performance. This material was chosen for its durability, easy availability but also for its cost-effectiveness.

The introduction of large-scale 3D printing has made Duo Form even more agile in the product development process. Now the company is able to:

  • 1

    Create full-size samples and prototypes in record time for customer validation

  • 2

    Customize each project with more flexibility than traditional methods

  • 3

    Reduce approval time by offering customers the opportunity to view and test parts before final production

This speed allowed Duo Form to acquire new clients and increase the volume of work, reducing the time needed to conclude negotiations. For the client, being able to view his final project as early as the quotation stage is definitely an added value.

From physical warehouse to digital inventory

One of the most significant advantages of additive manufacturing is the ability to store molds in a digital format. This innovative approach enables Duo Form to:

  • 1

    Eliminate the cost of physical storage of molds

  • 2

    Reproduce discontinued components with ease and on demand

  • 3

    Avoid waste and obsolescence by printing only when needed

“We have experienced a sharp increase in work volume with the Titan 3D printer. The rapid production of parts, molds, and formed parts has enabled us to make great strides over the competition.”

David Rheinheimer Product Development Manager at Duo Form

The integration of large-format 3D printing with traditional thermoforming techniques thus enabled Duo Form to optimize resource management and maintain high quality standards. 3D Systems’ Titan EXT 800 Pellet proved to be a fast, cost-effective and sustainable solution.

 

 

If you would like to find out how this technology can optimize your production, contact a 3DZ expert for a personalized consultation!

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