If you're forming end parts in the FormBox, you might need to do some manual or automated post-processing to achieve the desired finish. In this guide, we'll explore different manual post-processing workflows and tools that you can use to cut and finish your parts.
Note: 1.5mm sheets are the maximum thickness that can be used with the FB without running the risk of damaging the trays
Note: Materials thinner than 0.25mm could be used in theory, but they might not get clamped very tightly between the trays and require testing.
Manual post-processing tools
General list of tools, what they’re for and links to recommended brands:
Essential tools:
- Kevlar scissors
- Bandsaw
- Disc sander
- Scalpel + blade
- Dry PTFE
- Heat proof gloves + working gloves
- Eye protection
- Ear defenders
Scissors
Scissors are a versatile tool for freehand cutting thin materials, such as Flex sheets, 0.5mm Clear sheets or Form sheets. They are particularly useful for cutting thin materials without the need for guides or tools. With their ease of use and accessibility, scissors are a great addition to your post-processing toolkit.
Kevlar scissors
Kevlar scissors are designed to cut through tougher and thicker materials that could damage regular scissors. In general we recommend using a band saw first to cut away excess material providing a basic shape, followed by a second pass with kevlar scissors for precision cutting. Finally, neaten the edges with a file or sandpaper.
Ultrasonic cutter
When dealing with tough materials like 1mm Clear sheets, ultrasonic cutters can make the task a lot smoother. To ensure optimum results, it is recommended to use a powerful ultrasonic cutter with a longer blade. Mastering the technique of using such a cutter might require some practice as it’s important to be mindful of the blade's access points and cut angle to avoid blade blunting or melting.
It is also crucial to stay safe by wearing protective equipment and operating in a well-ventilated area since plastic fumes are emitted during the process. Wear goggles, ear defenders and respirator. Cut gloves are also recommended. Plastic fumes are released when cutting with the sonic knife.
Scalpel
If you need to cut thin materials like 1mm Flex or 0.5mm Clear/Form sheets scalpels can be a useful tool. They are particularly effective for achieving precise cuts and finishing touches.
Dremel / Bobbin Sander
Handheld rotary power tools, such as the Dremel, come with a wide range of accessories for various tasks, including cutting and finishing parts. The cutting discs can be used to cut thin materials, and the sandpaper accessory can remove excess material from thicker parts.
Band saw
The band saw is an essential tool for cutting rigid materials. It is a fast and reliable way to remove excess material and can be combined with more precise tools like the Dremel or ultrasonic cutter for greater precision.
If your working area doesn’t have room for a band saw, an electric jigsaw can be a great alternative, offering similar results and material compatibility.
For example, when cutting an ABS part, you would first use the band saw to do two passes: one to remove excess material and a second to get closer to the outline. Then, the edges would be sanded with a Dremel for a more consistent finish.
Note: It can cause delamination of multilayered materials e.g. fiberglass and FFF tools.
Jig-assisted cutting
When post-processing thin parts (1-1.5mm), it can be helpful to design and create a jig to guide you during the cutting process. This jig can be made using 3D printing or other technologies.
In the example below, you can see how a formed part (white) was cut with high precision thanks to the use of a 3D printed jig (black).
Manual post-processing examples for Mayku Materials
Form sheets 0.5mm
Our Form sheets come in 0.5mm thickness, making them easy to post-process. After forming a blister packaging prototype, we removed the excess material with Kevlar scissors. Then, we used a 3D printed jig along with a cutter to trim the edges and achieve a consistent finish.
A band saw could have been used as an alternative, but we preferred Kevlar scissors because they didn't generate dust that would have required cleaning later.
Flex 1mm
Thanks to the flexible nature of the Flex sheet, de-molding small parts is extremely easy, and it also allows for easy part cutting using scissors, cutters, or scalpels.
If you're making a two-part mold using Flex, consider using the Pro Mesh instead of the origional mesh that comes with teh FormBox. This will create a permeable flat layer and prevent the Flex from capturing the dimple pattern produced from the Mayku forming bed.
Finding the best solution for you
This guide has presented manual post-processing tools and how to integrate them into your workflow. However, it's important to note that each team has a unique workflow, and each design may present unique challenges. We highly recommend testing different post-processing methods to find the one that suits you best.
Based on our experience, a band saw (or similar tool) is essential when working with thicker and more rigid materials. Other tools, such as ultrasonic cutters or the Dremel, are key to achieving high-quality part finishing.
Automated post-processing methods
Designing for CNC
The key to precise CNC work lies in aligning the physical workpiece with the CAD software to the minimum tolerances.
Click here for more information on Automated post-processing methods.