The Challenge of Traditional Tooling
A regional healthcare logistics venture needed to produce 250 custom blister packaging trays for a temperature-sensitive diagnostic reagent kit. Traditional CNC aluminum mold tooling quotes came in at $4,200 with an 18-day machining and polishing lead time.
For a startup validating packaging integrity and cold-chain fit, spending thousands of dollars before finalizing tray dimensions was unacceptable.
The Additive Tooling Solution
FamilyMake designed and 3D printed the vacuum-forming mold buck using heat-resistant engineering resin capable of withstanding 120 °C under continuous cyclic vacuum pressure:
- Micro-Vent Hole Integration: Vacuum holes (0.6 mm diameter) were modeled directly into internal deep draw pockets, eliminating manual post-print drilling.
- Draft Angle Optimization: All vertical walls included a 3-degree draft angle to ensure clean, non-stick sheet release.
- Thermal Mass Infill: The mold was backfilled with high-temperature epoxy to absorb sheet thermal cycles without softening.
Outcome
The mold buck was printed in 14 hours and tested on a commercial vacuum thermoformer with 0.8 mm PETG film that same afternoon. The entire run of 250 blister trays was formed within 48 hours of initial CAD upload, saving over $3,500 in tooling costs.
