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

1. 1. Always applying draft angles of at least 5° and add air holes
2. 2. Use registration features to help align parts during assembly
3. 3. Consider material thickness when calculating the size of the final part
4. 4. For the CAD workflow, start by designing the outer shell and work inward
5. 5. Always aim to avoid undercuts

All three components follow the same forming process, differing only in material settings:
 

1. 1. Apply 4 coats of Dry PTFE Spray from WD40 to the tool, allowing it to dry completely between each coat. This allows for easier mold release after forming
2. 2. Select sheet material, remove any protective film and place in the reducing plate
3. 3. Follow the on screen instructions to begin the pressure forming process
4. 4. When de-molding, gently flex the part and push from the centre of the form to release the tool
5. 5. Download our guide to discover which Custom Mode settings we chose for forming

1. 1. Prior to assembly, drill 3mm holes in the designated areas of each part
2. 2. Clean all components, ensuring there's no residue or debris from the forming and cutting steps
3. 3. Align the three components and bolt them together using M3 cap head socket screws
4. 4. The tail-light is now complete