Looking for a way to create precise prototypes, molds, or end-use parts for final products? Look no further than the Mayku Multiplier, a professional and easy-to-use pressure forming machine.
In this blog post, we'll cover the steps for creating an automotive prototype using the Mayku Multiplier. We'll start with design tips, move on to manufacturing and forming, and finish with post-processing techniques.
About the Mayku Multiplier
The Mayku Multiplier is an intuitive desktop pressure forming machine that enables you to create precise prototypes, molds, and end-use parts with ultra-high detail. It can capture surface details as small as one micron, including surface texture, layered surfaces, and other features.
The Multiplier provides full control of the process and is perfect for small batch production. Its design and controls make it easy to use and offer fast results.
The pressure forming workflow
Here, we present an example Multiplier workflow, from idea to final part. It is important to note that each project is unique and may require different or additional steps.
Step 1: Designing the template
To start, you'll need a template that gives the formed plastic sheet its precise shape. First, draft angles are essential as they make demolding much more comfortable. The more draft, the easier it is to remove the formed sheet from the template.
Undercuts should be avoided as you won't be able to remove the object once the plastic sheet cools down. However, with our flexible EVA sheets, you can form parts with small undercuts as well as vertical walls.
Non-porous templates should have air holes, allowing the sheet material to form inside of internal voids without trapping any air.
These are some of the key design principles you should consider when designing your template. Find here a complete guide on design for thermoforming.
Step 2: Manufacturing the template
Once you have your template design, it's time to manufacture it. You can use various technologies to manufacture a template, including CNC and laser cutting. When making a template, make sure it has high-temperature resistance and strength as it needs to withstand the pressure forming process. For our project, we're making the template with high-temperature resin.
Step 3: Choosing the Material
Once the template is ready, choose the material you want to form with. At Mayku, we have an expanding range of materials, all of which come with tested profiles to guarantee a smooth forming process.
Some of our materials, such as PETG have a protective film, so make sure you remove this before placing the material in the machine.
For our project, we'll be using 4mm ABS, which offers high stiffness, excellent impact, and chemical resistance.
Step 4: Forming Process
Now it's time to start the forming process with the Mayku Multiplier. Open the lid of the machine and position the material on top of the guides.
Bring the lid down and turn the top lock to hold the material in place. Once the material is in place, you'll hear the air tanks compressing below the forming area. The heating process starts automatically while the air tanks are compressing.
Once the heating process is almost complete, position the template on the forming area. You can place multiple objects on the forming area at the same time or just one large template.
If your template has complex design features that can make demolding more difficult, you may want to coat it with a release agent such as dry PTFE.
The Multiplier heats the sheet to the optimum temperature, and when the on-screen instructions alert you that the machine is now ready, bring the lid down and slide the bottom lock to prepare the machine for forming.
Press the button to release five tonnes of pressure into the forming chamber. You will hear a noise as pressure is released. When the cooldown process finishes, the air will be released from the pressure chamber. Now release the locks and open the Multiplier.
Step 5: Post-processing
Now it's time for post-processing. Once you have the final part, you need to remove the excess material. There are many ways to do it, depending on the sheet material you used and its thickness. For thinner and flexible materials, hand-cutting them with scissors or a knife will work great. If you're using thick or rigid materials, like in our case, using electric tools like a bandsaw, drill, or a rotary power tool is highly recommended.
Also, if you're using the Multiplier for small batch production, consider making a jig to quickly and accurately post-process the part.
Conclusion
With the Mayku Multiplier, you can create high-quality, high-detail parts in less time, with full control of the process. It's perfect for producing precise prototypes, molds, or end-use parts that can be used on final products.
The Mayku Multiplier is an innovative machine that makes the process of creating high-quality parts easy and intuitive. We hope this guide has given you an idea of how to use the Mayku Multiplier and post-processing techniques. Continue exploring our online resources to learn more about producing with the Mayku Multiplier.
