Case Study: Duo Form Achieves Faster, Lower-Cost Thermoforming Production with 3D Systems Pellet Extrusion 3D Printing

Duo Form Adopts Pellet Extrusion 3D Printing for Large Thermoforming Molds

Duo Form, a leader in thermoforming for a wide range of industries, needed to shorten lead times, lower costs, and maintain mold quality while improving design iteration and prototype approval. To address these challenges, Duo Form turned to 3D Systems and its EXT 1270 Titan Pellet 3D printer for large-format additive manufacturing of production molds, tools, and sample parts.

Using 3D Systems’ pellet-extrusion printing with glass-filled polycarbonate pellets, Duo Form replaced traditional CNC-made ceramic or metal molds with faster, lower-cost 3D printed alternatives that also support vacuum-forming porosity. The result was significant cost savings and shorter production cycles, plus faster customer approvals and more business; in one case, a 3D printed sample helped Duo Form win a bid the same day it was quoted.

Duo Form

David Rheinheimer

Product Development Manager