Fused Deposition Modeling

In an effort to improve efficiency and reduce waste, custom thermoformer Plastic Ingenuity (PI) has purchased a Fused Deposition Modeling (FDM) machine to provide additional means for creating sample molds. The FDM process builds objects by fusing layers of molten plastic on top of each other, stacking these plastic layers until the object is complete. This additive fabrication process creates minimal waste, uses less raw material, and helps reduce costly re-tooling. Additive fabrication differs greatly from the traditional subtractive processes common in the industry, such as milling, turning, or drilling, which use programmed tool paths to remove material from a solid block to form the desired shape. The process to print/form a mold is relatively simple and requires a minimal amount of set up time. The total machine set up time is fewer than 10 minutes, no matter the size or complexity of the mold. This 10 minute procedure replaces a full day of programming required for traditional sample mold building. Once the job is uploaded, the FDM machine runs unattended until the part is complete. When finished, the engineer extracts the part from the build area and delivers a completely functional sample mold ready for the prototype process. The build material is placed in the machine in pre-packed canisters. The machine monitors the amount of material that is used, and automatically switches from one canister to another when necessary, eliminating the need for human intervention. The FDM machine creates sample molds that are of much higher quality and more durable than molds created from traditional rapid prototype machines. Build times for the molds range from approximately 2.5 hours to 15 hours, with this duration based primarily on mold size, not complexity. Intricate graphics or print engravings may not have the detail of an aluminum mold, but are effective for depicting location and size. Plastic Ingenuity continues to invest in equipment and technology to improve packaging and packaging systems for its customers, reduce lead times, and improve upon an industry leading speed to market.