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Printer settings
Using a CAD modeling software, you can easily get the surface area of your mold. If you do not have the exact number, you can approximate it by taking general measurements and assuming it as a simple geometry.
Using a CAD modeling software, you can easily get the surface area of your mold. If you do not have the exact number, you can approximate it by taking general measurements and assuming it as a simple geometry.
The footprint is the heated area of the plastic sheet and can be easily found if you know the dimensions of your machine.
The footprint is the heated area of the plastic sheet and can be easily found if you know the dimensions of your machine.
=== Edges / Fillets ===
=== Edges / Fillets ===
Whenever you create a part for vacuum forming, you want to avoid sharp edges or sharp angles as much as possible. The thicker your plastic is, the less capable it will be to take the shape of those sharp corners. The thinner the material is, the more susceptible it is to overstretching.
Whenever you create a part for vacuum forming, you want to avoid sharp edges or sharp angles as much as possible. The thicker your plastic is, the less capable it will be to take the shape of those sharp corners. The thinner the material is, the more susceptible it is to overstretching.
[[File:Edges Fillets.png|center|thumb|360x360px]]
[[File:Edges Fillets (1).png|alt=|center|thumb|360x360px]]
== Printer Settings ==
Once your 3D model of your mold is complete, it is time to print it. This is the part where slicer settings and filament selection will help the most towards the durability of your mold. Starting with your slicer settings, the following should help your mold best trough the process of vacuum forming. It is possible that settings may need additional adjustments depending on your filament and type of plastic you are forming. Using these settings, you can expect to get up to 10 pulls for 0.25mm to 0.5mm and up to 5 pulls for 1mm and thicker.
=== Layer Height ===
As per usual, the lower the layer the better the resolution of the print, but the longer it will take to print. Since the plastic sheet is formed onto the mold, every details will transfer to the sheet, even the smallest layer lines. A solution to get the best of both worlds (fast printing time and a good surface finish) is sanding the part down. Anything above 400 grit (the higher the better) will give a good enough finish compared to big layers. In the end, it is all up to your preferences. A good place to start is 0.16mm layers (for a standard 0.4mm nozzle) and calibrate from there to your liking.
=== Infill ===
The infill can affect affect the structural integrity of your mold and dictate the amount of pulls it will be able to sustain. It also affects the amount of material you will be using and therefore the time the print will require. The recommended infill density for most molds applications is 20%. For the infill pattern, the Gyroid pattern offers a good balance between time efficiency and structural durability.