Challenge: Improving the Thermoforming Mold-Making Process
REV Group, a fire truck manufacturer, relied on traditional wooden molds for their thermoforming process. However, with their in-house tool maker retiring, they needed a faster, more cost-effective alternative to produce molds efficiently while also addressing the storage challenges of legacy molds.
The conventional approach required months for mold production, high labor costs, and large storage facilities to house physical molds. To remain competitive, REV Group sought a solution that could streamline mold production, improve vacuum performance, and reduce overall costs.
Solution: 3D Printing with Pellet Extrusion Technology
ADDMAN introduced pellet extrusion additive manufacturing using the EXT 1070 Titan Pellet 3D printer to replace the traditional wooden mold-making process. This solution allowed for:
- Rapid, cost-effective production of thermoforming molds, eliminating the need for a dedicated tool maker
- Digital inventorying of molds, reducing warehouse storage costs
- Optimized mold design for better vacuum pulls and streamlined post-molding processes
- 3D-printed trim tools, enhancing efficiency in secondary CNC trimming operations
ADDMAN also digitized existing wooden molds, enabling on-demand mold printing when needed. This eliminated the need for large-scale mold storage while ensuring a continuous supply of production-ready molds.
Benefits of Additive Manufacturing for Thermoforming
Improved Vacuum Performance
Using ADDMAN’s patented tool pathing process, the porosity and density of the mold were carefully controlled, allowing for precise airflow distribution in specific areas to optimize vacuum performance. This led to:
- Better material distribution during forming
- Reduced defects and improved cycle times
- Enhanced consistency across production runs
Simplified Mold Design
Traditional wooden molds required baffles, boxes, and drilled vacuum channels to function properly. With 3D printing, these features were designed directly into the mold, eliminating extra steps and allowing for a more streamlined mold structure.
On-Demand Trim Tools for CNC Processing
In thermoforming, excess sheet stock must be trimmed after molding. ADDMAN 3D printed custom trim tools, designed specifically for each mold and panel, enabling faster and more precise CNC trimming while reducing setup time and cost.
Results: Faster Turnaround, Lower Costs, and Greater Efficiency
The transition from wooden molds to 3D-printed thermoforming molds dramatically improved REV Group’s production process:
- Turnaround times reduced from months to days or weeks
- Faster cycle times due to improved vacuum pulls and material flow
- Significant cost savings through reduced labor, automation, and pellet-based feedstocks
- Eliminated the need for large warehouse storage, cutting long-term operational expenses
By leveraging pellet extrusion 3D printing, ADDMAN helped REV Group modernize their thermoforming process, improve production speed, and drive cost efficiencies—an example of how additive manufacturing is reshaping traditional industries.