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An innovative approach to additive manufacturing consists in the possibility of producing moulds that can be used for traditional manufacturing processes such as thermoforming. The quality and dimensional precision of the interior surfaces of the plastic foils obtained after thermoforming is closely related to the used mould. The influencing factors considered are the different thermal and mechanical properties offered by the wide range of available plastic materials for additive manufacturing (AM), the multitude of printing parameters, and the technological process by means of which the mould was obtained. For the production of plastic moulds, Fused Filament Fabrication (FFF) and Selective Laser Sintering (SLS) processes, as well as materials specific to each technology, are used. This paper identifies and explains issues concerning the surface quality of the thermoformed foil through a systemic analysis approach and by conducting laboratory experiments. Optical 3D scanning equipment and software are employed to determine the proper additive process and materials for thermoforming process. The best quality of the finished product was obtained in the case of a male mould made by the SLS technology and PS foil with a thickness of 0.7 mm.

Theoretical and experimental research on the quality of thermoformed foils using 3D-printed plastic moulds