There are some things to consider when designing a 2-part tool for thermoforming. In order to achieve optimum results, we suggest: 
 

1. 1. Apply draft angles of at least 5°
2. 2. The thickness of the wall must be higher than the width of two sheets of material used for manufacture - if less, they will not fit inside one another
3. 3. There needs to be a flat, continuous surface on both sides that will allow the two halves to be glued together
4. 4. Use registration features that will make sure that the two halves align well during gluing

1. 1. Apply 4 coats of Dry PTFE Spray from WD40, allowing it to dry completely between each coat. This allows for easier mold release after forming 
2. 2. Select sheet material and remove any protective film. We used HIPS 1mm
3. 4. When placing the tools on the forming bed, ensure there is at least a 15mm gab between the two separate tools
4. 5. When de-molding, gently flex the part and push from the centre of the form to release the tool 
5. 6. Download our guide to discover which Custom Mode settings we chose for forming

1. 1. It's important to set up the jig and cutting path correctly to ensure repeatability which is essential for batch production
2. 2. The 3D printed tool which was previously used for the thermoforming can now be used as a jig.
3. 3. We suggest laser cutting a path based on the base of the 3D printed tool from a sheet of MDF which can then be fixed to the laser bed. The tool positioned in the laser cut part of the MDF sheet becomes the jig 
4. 4. We can now put the trimmed and glued product casing onto the jig which will hold it in place during the cutting process
5. 5. The cutting path for the product casing is referenced to the cutting path of the jig meaning that the laser will precisely cut the excess border off, leaving you with a perfectly cut final part