Case Study: Original Appearance Manufacturing achieves faster, cost-effective, and durable thermoforming production with ExOne’s X1 ThermoForm 3D-printed tooling

3D Printed Sand Tooling Proves Durability in Production

Original Appearance Manufacturing (OAM), an aftermarket automotive panel maker in Ames, Iowa, faced unsustainable traditional tooling: handmade steel, composite, or wood tools required frequent repair and limited precise vacuum-hole placement, while aluminum tooling was prohibitively expensive and slow for their low-to-medium volumes. Seeking faster, durable, and more flexible tooling to speed time to market, OAM turned to ExOne and its X1 ThermoForm infiltrated sand tooling for a binder-jet 3D printed solution.

ExOne delivered X1 ThermoForm sand tools (binder-jet printed, resin-infiltrated, coated) in about two weeks at roughly half the cost of aluminum tooling that would take over three months, enabling OAM to move from quarterly launches to monthly product releases. The tools maintained part quality through 500+ pulls with no visible degradation, demonstrated 99.99% or better dimensional accuracy in quality scans, ran 0.060" ABS pulls at ~3:50–4:05 minutes forming at 290–305°F with tool surface temps under 180°F, and have positioned OAM to pursue multi‑year tool lifespans and higher, previously unprofitable product volumes — all delivered by ExOne.

Original Appearance Manufacturing

Zach Kowalik

Chief Executive Officer