Storm Trooper Food Mould

Printed using fused deposition modelling (FDM) in a high temperature material (ULTEM) this model was for reference prior to CNC of a vacuum forming tool. Due to the loose layering on an FDM model air can still be pulled through making this a perfect process to vacuum form over Thermoforming.

Thermoforming is the collection of manufacturing methods that heat and form sheets of extruded plastic. It is a relatively simple process that starts with heating a plastic sheet to a pliable state. Once softened, the sheet is forced against a mould with the desired shape using different methods: In vacuum forming, a vacuum is drawn through tiny holes in the mould. In pressure forming, air pressure is applied to the surface.