Understanding thermoformable materials

The Multiplier comes with Mayku material profiles set as standard on the machine. These are available from resellers and our website. The current standard Mayku materials are:

• 1mm PETG
• 1mm HIPS
• 1.5mm EVA
• 3mm PMMA
• 3mm UHMW
• 4mm ABS
  
  

Important info:

Material size

Sheet materials are circular, with a diameter of 428mm. If the circular sheets are cut any bigger or smaller, you might struggle to align the sheet with the machine pins.. The sheets are clamped in place during the forming process, which means the recommended safe forming area is 380mm. Circular sheets are used for optimal heating and pressure.

Material thickness

The Multiplier can form sheets with  thicknesses between 0.5mm to 5mm. The Multiplier can also form sheets between 5 - 8mm thick, and as thin as 100 microns, with the help of the Reducing Plate.

Material categories:

• Rigid e.g. PETG, HIPS. PMMA. ABS: Not self lubricating; Difficult to mold without recommended design considerations. Recommendation: 8 degree draft angles
• Non-stick e.g. UHMW: Very low coefficient of friction; is self-lubricating and easier to demold with 5 degree draft angles
• Flexible e.g. EVA: 0 degree draft angles, case specific undercuts are possible

Environment

Make note of your environment; a strong wind, an open window, a sunny day can influence and slow the heating process of the plastic. Thick high temperature plastics have higher success rates in warm temperatures. 

Humidity

Humidity (some materials are hygroscopic and should be kept in controlled conditions for consistent results) e.g ABS, PMMA, and PETG should be kept in a sealed bag.

Common thermoforming materials

When it comes to thermoforming, the choice of material is hugely important. It is essential to choose a material that is compatible with the desired application and the end product. Different materials have different properties and capabilities, so it’s helpful to understand these materials in order to make an informed decision.

Below are some of the thermoforming materials compatible with the Mayku Multiplier:

Mayku Materials

EVA (Ethylene-Vinyl Acetate)

EVA (ethylene-vinyl acetate) is a versatile material known for its flexibility, strength, and shock absorption capabilities. It is commonly used in cushioning applications like protective packaging and shoe soles. EVA is also used in the production of hot melt adhesives and pressure-sensitive tapes. It is gaining popularity in various industries due to its easy processing and recyclability, making it an environmentally friendly choice.

It is flexible and resistant to many materials, such as resins, making it ideal for creating reusable molds as it’s easy to demold. It is non-toxic and can withstand temperatures ranging from -35 °C to 60 °C.

• Forming temperature: 130°C
• Shelf life: EVA, especially in its raw form, can retain its properties for several years under ideal storage conditions.
• Storage: Store EVA in a cool, dry place away from direct sunlight. EVA can be susceptible to oxidation over time, so reducing exposure to air can be beneficial.*

Here are some reasons why you may considering choosing EVA for your project:

• Shock absorbent capabilities
• Insulating and waterproofing properties
• Easy to process and recycle
• Excellent flexibility
• Good strength
• Tear resistant
• UV resistance

Learn more: Mayku Multiplier EVA

PETG (Polyethylene Terephthalate Glycol-modified)

PETG (polyethylene terephthalate glycol) is a rigid material with good impact resistance and great thermal characteristics, allowing it to cool efficiently without warping. It has superior chemical resistance compared to many other transparent plastics, making it a top choice for food-safe packaging, molds and transparent prototypes. PETG is recyclable and considered food safe, making it an eco-friendly and safe material for food contact applications.

• Forming temperature: 160°C
• Casting temperature: If being used for casting, molds made from PETG will start deforming at around 60°C. We recommend keeping your hot casting materials below 50°C to avoid damaging your molds. 
• Shelf life: As a raw material, PETG in pellet or sheet form can last several years under proper storage conditions. Once processed into a product, its lifespan will vary based on the use-case and environment.
• Protective film: Our PETG sheets come with a protective film. Make sure to remove before use.
  Storage: Store in a cool, dry place away from direct sunlight, in the sealed bag provided. PETG can absorb moisture, so keeping it sealed or using desiccants can be beneficial, especially before thermoforming.* 

   

Why should you choose PETG for your product?

• Easy to fabricate
• Fast cycle times, particularly at thinner gauges
• Food safe
• Semi-rigid
• Good impact resistance
• Optically clear
• Good chemical resistance
• Smooth and clean surface finish

Learn more: Mayku Multiplier PETG

HIPS (High Impact Polystyrene)

HIPS (high impact polystyrene) is a lightweight and durable thermoplastic. It is produced by combining styrene monomer with a rubber-like polymer called polybutadiene, resulting in a hard and rigid plastic. HIPS is easy to process, relatively inexpensive, and can be colored and decorated with silk-screen printing. HIPS offers a combination of stiffness, impact strength, and dimensional stability, making it suitable for applications that require these qualities.

• Forming temperature: 160°C
• Shelf life: HIPS can last several years when stored properly.
• Storage: HIPS should be kept in a cool, dry place. It is also sensitive to UV light, which can cause discoloration or brittleness, so keeping it away from sunlight is crucial.*

These are some of the advantages of HIPS:

• Highly durable and resistant to impact
• Easily machinable and formable
• High temperature and chemical resistance
• Good dimensional stability
• High stiffness and strength
• Good electrical insulation
• Low cost

Learn more: Mayku Multiplier HIPS

Mayku Engineering Materials

PMMA (Acrylic)

Acrylic, also known as PMMA (polymethyl methacrylate), is a transparent material with high impact and chemical resistance. It is often used as a glass alternative due to its excellent optical clarity. It is lightweight, easy to handle, process, and cost-effective, making it suitable for various applications.

• Forming temperature: 200°C
• Shelf life: PMMA sheets and products can last for many years. However, prolonged exposure to UV radiation may cause them to become less transparent or slightly yellow over time.
• Storage: To prevent discoloration, store PMMA in a cool place away from direct sunlight, in the sealed bag provided. . Avoid contact with solvents or chemicals that may cause crazing or cracks.*

Why choose PMMA for your product? Here are some reasons:

• Easy fabrication
• Optical clarity comparable to glass
• High resistance to UV light
• Good stiffness
• Good abrasion resistance

Learn more: Mayku Multiplier PMMA

ABS (Acrylonitrile Butadiene Styrene)

ABS (acrylonitrile butadiene styrene) is a commonly used thermoplastic known for its strength, impact, chemical and heat resistance, and rigidity. ABS is easy to process and highly versatile making it a great choice for a wide range of applications, especially for enclosures that need to withstand wear and tear.

• Forming temperature: 170°C
• Shelf life: ABS, especially as raw material for 3D printing or injection molding, can last several years with proper storage.
• Storage: ABS can absorb moisture, which can cause issues during processing. Store in a cool, dry place, ideally in a sealed bag with desiccants if meant for 3D printing. Prolonged UV exposure can cause discoloration and brittleness, so keeping it out of sunlight is recommended.*

These are some of the main benefits of ABS:

• High stiffness
• Easy to process and bond
• Good impact resistance at low temperatures
• Good gloss surface finish
• Excellent chemical resistance

Learn more: Mayku Multiplier ABS

UHMW (Ultra-high molecular weight polyethylene)

UHMW (ultra-high molecular weight polyethylene) is a highly durable and resilient form of polyethylene. It has a low friction coefficient, allowing for easy sliding on any surface without sticking or binding and therefore resistant to resins. It's worth remembering that UHMW is a rigid material so adding a 5 degree draft angle is recommended. It is lightweight, has some flexibility, and is chemical-resistant. Overall, UHMW is a superior alternative to traditional steel components due to its durability, non-stick properties, and high impact resistance.

• Forming temperature: 200°C
• Shelf life: UHMW has a long functional lifespan, often lasting several years in demanding applications.
• Storage: It's best to store UHMW in a dry environment away from direct sunlight. However, UHMW is notably chemically resistant and isn't as affected by moisture as some other plastics.*

Why pick UHMW for your product? Here are some reasons:

• Ultra low friction and non-stick
• High impact resistance
• High strength
• High tensile strength
• Abrasion resistant
• Chemical resistant

Learn more: Mayku Multiplier UHMW

Read this before using the new engineering materials

Mayku have released three engineering-specific materials: UHMW 3MM, ABS 4MM and PMMA 3MM. 

There are certain considerations you should take into account when using these advanced materials with your Multiplier that you can read about below. 

Cooling cycles 

Our engineering materials have higher forming temperatures due to their material properties and thicknesses.

This means that they can retain much greater amounts of heat than our thinner materials and require keeping the machine at higher temperatures in order to make optimal forms. In order to keep the machine safe to use, the machine needs to be kept below a certain temperature for repeated use.

We have therefore implemented a cooling system after each form that checks that the machine is below the needed temperature before being used again in another cycle. If the machine was to be used immediately after forming, the overheating sensor on the machine will trigger and the machine will shut itself off and will require a restart.

In order to speed up the cooling process, you can manually cool the dome by directing a fan towards the inside of the dome. This will significantly reduce the cycle time for our engineering materials.

Breezes and drafts

Even a light breeze or draft can have a surprisingly impactful effect on the heating of a sheet material. It means that the heaters have to be working harder to heat the material and therefore more residual heat can build up around the dome.

To avoid this, make sure there are no drafts or breezes that could affect the operation of the machine whilst it is heating. You can reopen windows and doors once the forming has taken place.

Other thermoforming materials

• PP (Polypropylene): PP is a popular thermoforming material due to its desirable characteristics, such as heat, chemical, and fatigue resistance, as well as its cost-effectiveness. It is used to make storage containers, medical devices, and sporting goods.                                               

  Note: PP can be a tricky material to form due to its tendency to expand and therefor doesn't heat evenly so testing is required.

• LDPE (Low-Density Polyethylene): LDPE is a chemical-resistant material with high strength and slight flexibility. It’s used for industrial packaging, plastic films and beverage containers.
• HDPE (High-Density Polyethylene): HDPE offers similar properties as LDPE, but it has increased density and more resistance to stress cracking. It is used for containers, bottles and automotive components.
• PC (Polycarbonate): PC is a strong, heat-resistant, and weather-resistant material. It is used for safety equipment, lighting, aircraft parts and electronic devices. (Note: PC absorbs moisture that bubbles up when heated and requires pre-baking - You can dry out PC in an oven at around 90-120 degrees C for 6-12 hours (the longer the better), testing is required on a case by case basis.

If you are using third-party materials, we recommend contacting the material manufacturer/seller prior to using the material in the Multiplier to confirm if the material you are using releases harmful fumes as it melts.

For example, do not use PVC as it can release chlorine gas if it burns. Using materials that release harmful fumes is at your own risk. Using a mask and fume extractor is recommended.

Please note: While these general guidelines can provide a foundation, specific storage needs might vary based on additives, specific formulations, or product requirements. Always consult with the material's data sheet or manufacturer for precise recommendations.

Mayku takes no responsibility for incompatible, hazardous or dangerous materials being used with the machine and custom mode - users should check the health and safety requirements of materials from third party suppliers.