POST-PROCESSING GUIDE

FOR PROFESSIONALS
 TABLE OF
MAKERBOT POST-PROCESSING GUIDE

CONTENTS
FOREWORD

Post-Processing Part 1
SILICONE MOLDING
P 7. WITH 3D PRINTED MASTERS

Post-Processing Part 1
SILICONE MOLDING
P 17. WITH 3D PRINTED MOLDS

Post-Processing Part 2
INSTALL THREADED INSERTS
P 22. IN YOUR 3D PRINTS

Post-Processing Part 3
VACUUM FORM USING
P 28. 3D PRINTED MOLDS
PAGE 2
POST-PROCESSING

PAGE 3
YOUR 3D PRINTS | A PRIMER

FOREWORD
MAKERBOT POST-PROCESSING GUIDE

Spraying all mold surfaces with mold release and fasten mold pieces together with rubber bands.
 3D printing can bring your ideas to life, but sometimes your ideas don’t stop
MAKERBOT POST-PROCESSING GUIDE

with 3D printed parts. What if your ideas call for multiple materials? Or a
smoother surface? What if your ideas are larger than the build volume of
your 3D printer?
Post processing isn’t necessary, but finishing techniques like sanding, gluing,
painting, and silicone molding can refine your prints and take your ideas far
beyond the build plate.
FOREWORD

SILICONE MOLDING WITH 3D PRINTED MASTERS SILICONE MOLDING WITH 3D PRINTED MOLDS

INSTALL THREADED INSERTS IN 3D PRINTS INSTALL THREADED INSERTS IN 3D PRINTS

PAGE 4
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 Post-Processing Guide Part 1

SILICONE MOLDING
SILICONE MOLDING
WITH 3D PRINTED MASTERS P 7.
SILICONE MOLDING
WITH 3D PRINTED MOLDS P 17.
PROJECT 01: CLOUD T YPES AND DISPL AY STANDS
 POST-
SILICONE MOLDING WITH
MAKERBOT POST-PROCESSING GUIDE

PROCESSING
3D PRINTED MASTERS
PART 1: SILICONE MOLDING

You don’t have to be an engineer, designer, or know about molding and casting to make a
silicone mold. Silicone molding is an inexpensive, easy, fun way to create objects in a number
of different materials, or to create a mold around a 3D printed part.

VIDEO TUTORIAL:
makerbot.com/professionals/post-processing/silicone-molding-1

MATERIAL S

3D printed mold Hot glue or

box, hardware, cyanoacrylate glue
vents & keys
Funnel
Master (the print
Hobby knife
you are molding)
Rubber bands,
Silicone
tape, or straps
Resin and dye
Gloves, eye
Mixing cups protection and
respiratory mask
Mixing sticks
Mold release spray
PAGE 7

Be sure to consult the safety precautions listed by the manufacturer on

any materials and equipment used in this tutorial before starting.
 STEP 01: CHOOSE A FILE TO

PAGE 8
CAST A MODEL AROUND

A. Print a part that you would like

to either make several of, or create
in a material not supported by your
printer. Here, we chose the cap to a
perfume bottle.

STEP 02: CREATE YOUR MOLD BOX

PART 1: SILICONE MOLDING

AUTODESK 123D AUTODESK 123D

A. Design a mold box to hold the silicone in place around your part when pouring. Your master will need to be
suspended in this structure. You can create mold boxes from foam core board, legos, or 3D printing.

Designing and 3D printing mold boxes allows you to create custom pour holes and vents, easily calculate the
volume of the mold, create boxes that perfectly fit the parts you plan to create a mold of, and re-use mold boxes to
create multiple molds.

MAKERBOT POST-PROCESSING GUIDE

MAKERBOT PRINT MAKERBOT PRINT

B. Prepare and print your mold box using standard “Balanced” print settings.
 STEP 03: SUSPEND MASTER IN MOLD BOX AND PREPARE
MAKERBOT POST-PROCESSING GUIDE

You can suspend your master using popsicle sticks, skewers, or 3D printed rods glued to the
surface of the master in an inconspicuous place. The holes left in their place after your mold
has cured will aid in resin flow through the mold.

A. Spray your mold box, master, vents, and keys with B. Choose points across model to glue vents.
mold release.
PART 1: SILICONE MOLDING
PAGE 9

C. Glue the master to the mold box. D. Spray again with mold release for good measure.
STEP 04: OPEN BOTTLES OF

PAGE 10
SILICONE (PARTS A AND B)

We calculated our mold

volume by filling our mold
box with water and pouring
the water into a measuring
cup to find exact volume.

PART 1: SILICONE MOLDING

STEP 05: MEASURE

MAKERBOT POST-PROCESSING GUIDE

A. Determine the volume of silicone needed to fill your B. Measure and pour the desired amount of silicone and
intended mold. hardener separately in two measuring cups.
 STEP 06: MIX SILICONE
MAKERBOT POST-PROCESSING GUIDE

Combine the two parts into one mixing cup and stir slowly with a mixing tool. Be cautious not
to stir in air bubbles. Scrape the sides of the cup to mix in all material. Once your parts are
thoroughly mixed the curing process will begin.
PART 1: SILICONE MOLDING
PAGE 11

TIP: Read instructions on your silicone for “pot-life.” This is how much time you have to work with the silicone
before it cures.
STEP 07: POUR MOLD (PART ONE)

PAGE 12
Pour silicone into the first half of your mold box. Pour slowly into one corner of the mold box
and allow the silicone to run to other parts of the mold box as it fills. Stop when the silicone
reaches the top of the box.

After you’ve poured the silicone, place small “keys” into the uncured silicone. These will create
negative spaces and allow the mold halves to fit together once poured. We will remove them
before pouring the second half of our mold.

PART 1: SILICONE MOLDING

MAKERBOT POST-PROCESSING GUIDE

STEP 08: LET CURE

Depending on what type of silicone you are using it can take anywhere from 75 minutes to
several hours to cure. Temperature and humidity will affect curing times, so we recommend
this process be done in a room temperature environment.
 STEP 09: ATTACH AND
MAKERBOT POST-PROCESSING GUIDE

PREPARE MOLD (PART TWO)

Repeat the process to form the second

half of the mold.

A. Remove the keys you inserted

in the previous step.

B. Attach and secure the second

half of your mold box.

C. Spray with mold release.

PART 1: SILICONE MOLDING

STEP 10: POUR INTO MOLD (PART TWO) STEP 11: LET CURE
PAGE 13

A. Repeat steps 5-8 to create the second half of

your mold using the methods mentioned above.
STEP 12: BREAK DOWN MOLD BOX

PAGE 14
A. Remove hardware. B. Remove the mold from C. Remove the master and vents.

PART 1: SILICONE MOLDING

the mold box.

STEP 13: REASSEMBLE AND PREPARE MOLD

MAKERBOT POST-PROCESSING GUIDE

A. Ensure that all parts of your mold are correctly B. Secure the mold pieces using rubber
aligned, and plug any holes created by vents. bands, straps, or tape.

TIP: If your vents leave holes in areas where resin can spill out during the pour, they will need to be plugged.
 STEP 14: MEASURE RESIN AND ADD DYE
MAKERBOT POST-PROCESSING GUIDE

Once you have mixed your resin, you will have only a few short minutes to pour your mold
following the steps below.
PART 1: SILICONE MOLDING

STEP 15: MIX RESIN

A. Combine both parts of the resin mixture

and mix thoroughly being sure not to stir in
air bubbles.

TIP: Resins typically have a shorter

PAGE 15

“pot-life” than silicone, meaning they

will cure faster.
 PAGE 16
PART 1: SILICONE MOLDING
STEP 16: POUR RESIN STEP 17: LET CURE STEP 18: OPEN & REMOVE

Once mixed, pour Once poured, allow Once your resin has cured, open
immediately into the the resin to cure for the the mold and remove your cast
opening of your mold appropriate amount of time. part. Any resin that escaped
using a funnel. Pour slowly through seams or voids and cured
and be careful not to is called “flash”. Flash will need
overfill and spill resin. to be removed from the part.

MAKERBOT POST-PROCESSING GUIDE

STEP 19: FINAL PART

Using this process, you can see that we were able to

recreate the perfume bottle cap in several different
colors and opacities.
 POST-
SILICONE MOLDING WITH
MAKERBOT POST-PROCESSING GUIDE

PROCESSING
3D PRINTED MOLDS
PART 1: SILICONE MOLDING

Silicone molding is a powerful production method when combined with 3D printing. In this
How To, we will show you some of the best practices associated with 3D printing molds to
pour into. To demonstrate this process, we will create a bicycle handlebar grip out of flexible
silicone using a 3D printed mold.

VIDEO TUTORIAL:
makerbot.com/professionals/post-processing/silicone-molding-2

MATERIAL S

3D printed mold
Mold release spray
Measuring/mixing cups
Mixing sticks
Hobby knife
Silicone
Gloves, eye protection
and respiratory mask

Be sure to consult the safety precautions listed

PAGE 17

by the manufacturer on any materials and

equipment used in this tutorial before starting.
STEP 01: PRINT MOLD

PAGE 18
BIKE HANDLE BAR GRIP MOLD: thingiverse.com/thing:103723

PART 1: SILICONE MOLDING

A. Prepare and print your parts using standard print settings.

STEP 02: PREPARE YOUR MOLD

MAKERBOT POST-PROCESSING GUIDE

A. Spray all mold surfaces with mold release and fasten mold pieces together with rubber bands.
 STEP 03: OPEN, MEASURE, MIX SILICONE AND ADD DYE
MAKERBOT POST-PROCESSING GUIDE

Once you’ve thoroughly mixed your silicone, you can pour it into your printed mold. Because we
used a slow curing silicone, we let this mold sit overnight to cure.

A. Measure part A B. Measure part B

PART 1: SILICONE MOLDING

C. Add dye to either part A or B (refer to D. Stir in dye

silicone/dye instructions).
PAGE 19
 PAGE 20
PART 1: SILICONE MOLDING
E. Pour mixture into mold. F. Insert third piece after pouring.

STEP 04: FINAL PART

Using this process, we created a flexible bicycle handlebar grip in a rubber-like material.

MAKERBOT POST-PROCESSING GUIDE

 Post-Processing Part 2
INSTALL THREADED
INSERTS IN 3D PRINTS

PROJECT 01: CLOUD T YPES AND DISPL AY STANDS

PROJECT 01: CLOUD T YPES AND DISPL AY STANDS
POST-
INSTALL THREADED

PAGE 22
PROCESSING
INSERTS IN 3D PRINTS

PART 2: INSTALL THREADED INSERTS

Threaded brass inserts can be a great way to add longevity to 3D printed enclosures that need to accept screws.
In this “how to” we will show you some of the best practices associated with installing threaded brass inserts
into your 3D printed enclosures.
Working time will vary depending on your model and how many inserts you plan to install. The process shown
took us about 10 minutes from start to finish.

VIDEO TUTORIAL:
makerbot.com/professional/post-processing/inserts/

MATERIAL S

Soldering Iron

MAKERBOT POST-PROCESSING GUIDE

Threaded brass inserts with
matching machine screws

Washers

Pliers

Vise

Heat resistant gloves

Eye protection

Respiratory mask

Need some of these products? We’ve curated an Amazon wish list for you.
 STEP 01: OBTAIN YOUR MODEL
MAKERBOT POST-PROCESSING GUIDE

LIGHT SWITCH BOX: thingiverse.com/thing:541876

A. When installing inserts, changing a few print settings in MakerBot Print can be a big help.
Increase the number of shells in your print. This will leave more plastic around inserts.
PART 2: INSTALL THREADED INSERTS

STEP 02: ROUGHING

PAGE 23

Supplies Used: Needlenose pliers

A. Once your model has been printed and removed from the build plate, remove any rafts or support material.
STEP 03: HEAT SOLDERING IRON

PAGE 24
Supplies Used: Soldering Iron
Allow your soldering iron to heat for 3-5 minutes before installing inserts. This will ensure that
you have to use the least amount of force to install inserts.

STEP 04: SECURE PRINT IN PLACE

Supplies Used: Soldering Iron

Before installing your inserts, it’s also

PART 2: INSTALL THREADED INSERTS

important that your model be secure. If
your model moves during installation of
an insert, you could damage the void or
even the model itself.
We used a multi-axis vice that allowed us
to work on the model from a few different A. Secure the model
angles.

B. Adjust the angle of the model

STEP 05:
PARTIALLY INSTALL INSERTS

MAKERBOT POST-PROCESSING GUIDE

Supplies Used: (continued use through
Step 9) Multi-axis vice, soldering iron,
threaded brass inserts, and pliers

Because PLA has a relatively low heat

deflection temperature and can deform at
moderate temperatures, it is important to
install inserts gradually.
A. Grasp your insert with pliers
B: Position insert over hole
 C. Press the insert half way into your print holding the
MAKERBOT POST-PROCESSING GUIDE

soldering iron vertically

D: Move on to the next insert

TIP: Push lightly, your soldering iron should do

most of the work for you

STEP 06: ALLOW TO COOL

As brass transfers temperature relatively quickly, your inserts should be cool within a minute or so.

STEP 07: COMPLETELY INSTALL INSERTS

Once you’ve allowed your model to cool for a minute or so, install the inserts until they are flush
with the top of your model.
When completing the installation of inserts be sure to avoid:
• Installing too quickly
PART 2: INSTALL THREADED INSERTS

• Pushing down on your inserts with too much force

CAUTION: Never attempt to hold inserts in place with your hand when installing. Always use pliers.

STEP 08: INSTALL SCREWS,

WASHERS OR OTHER HARDWARE

Supplies Used:
Screws & washers
Screwdriver
Multi-axis vice
Thread in your screws using a screwdriver
or drill.
A. Insert washers and screws
PAGE 25
 PAGE 26
CAUTION: Be sure not to over tighten. This can
force the insert free from the surrounding plastic.

If you over tighten your screws, you may need to

melt out your inserts and reinstall.

B. Insert additional hardware

PART 2: INSTALL THREADED INSERTS

STEP 05: FINAL PART

Here is our final part. After installing inserts, screws, and washers, we added the final switches
to this electrical enclosure.

MAKERBOT POST-PROCESSING GUIDE

 Post-Processing Part 3
VACUUM FORM USING
3D PRINTED MOLDS

PROJECT 01: CLOUD T YPES AND DISPL AY STANDS

PROJECT 01: CLOUD T YPES AND DISPL AY STANDS
POST-
VACUUM FORM USING

PAGE 28
PROCESSING
3D PRINTED MOLDS

PART 3: VACUUM FORM USING 3D PRINTED MOLDS

Vacuum forming is a manufacturing process by which a sheet of plastic is heated and pressed over a form to
create a part. This process is used to create many of the products in your home such as plastic containers, tubs,
sink units, and electrical enclosures.
3D printing is a great way for manufacturers to create low cost molds for low volume manufacturing or
prototyping.
While we used an industrial vacuum forming machine to achieve our application, you can also build one at
home to achieve the same effect.
While working time will vary, this process took us about 1 hour from start to finish.

VIDEO TUTORIAL:
makerbot.com/professional/post-processing/vacuum-forming/

MAKERBOT POST-PROCESSING GUIDE

MATERIAL S

Vacuum forming machine

Sheets of vacuum forming plastic

3d printed mold

Mold mounting fixture

Cutting tool

Eye protection

Heat resistant gloves

Need some of these products? We’ve curated an Amazon wish list for you.
 STEP 01: OBTAIN YOUR MODEL
MAKERBOT POST-PROCESSING GUIDE

LIGHT SWITCH BOX: thingiverse.com/thing:541876

In order to vacuum form you will need a

mold to vacuum form around. Your final
parts will be nearly exact replicas of your
mold.

You can download molds from sites such

as GrabCAD, but we chose to design ours.
For our model, we designed a common
taxi sign used to show whether or not cars
are available for service.

TIP: When designing a mold for vacuum forming consider drafting angles. Drafting angles allow your molded part
to be removed from the mold. They should typically be anywhere from 3-5 degrees from 90 on any vertical surface.

STEP 02: PREPARE AND PRINT MODEL

When preparing a model for vacuum

PART 3: VACUUM FORM USING 3D PRINTED MOLDS

forming in MakerBot Print, there are some

print settings that should be taken into
account.

We printed our model with 4 shells at 25%

infill.

Next, print your model. We printed our

model on the MakerBot Replicator Z18
because of the large size of our model.

TIP: Increase shells and infill settings to create a strong mold that will withstand the pressures of vacuum forming.
PAGE 29
STEP 03: PREPARE MOUNTING FIXTURE

PAGE 30
Because we used an industrial vacuum forming machine we needed to secure the mold to
an additional fixture. This holds the mold in place against the various forces that occur when
operating the machine.

PART 3: VACUUM FORM USING 3D PRINTED MOLDS

A. Drill or tap holes in an inconspicuous place on the B. Mount board to vacuum forming machine
underside of your print & attach to Small plate or MDF
board

STEP 04: LOAD AND HEAT PLASTIC

MAKERBOT POST-PROCESSING GUIDE

 A. Load your plastic.
MAKERBOT POST-PROCESSING GUIDE

We started with 12 x 24 inch sheets of white polystyrene plastic about .75mm thick and worked up to ¼ inch thick
sheets of PET-G.

When choosing plastic sheets for vacuum forming, consider the thickness of the plastic and the size of the sheet as
well. Thicker sheets will need to be heated to higher temperatures and will require a higher power vacuum.

B. Heat plastic to desired temperature.

Because we used an industrial vacuum forming machine, our plastic was heated automatically to temperature
based on the type of plastic, thickness, and density.

While 400 degrees fahrenheit is close to the melting point of PLA, only the sheet is heated and not the form. This
means the heat is not necessarily a concern in low volume production or prototyping.

TIP:
• Choose thinner sheets of plastic if your vacuum forming machine does not create large amounts of consistent
heat or suction.
• Typically plastics will be heated somewhere around 400 degrees fahrenheit.

STEP 05: PRESS PLASTIC OVER FORM

Once plastic is heated, it is pushed over the form.

At this point you will notice that the vacuum suction will pull all of the air out from under the
heated plastic sheet and it will be forced down over your mold.
PART 3: VACUUM FORM USING 3D PRINTED MOLDS

The plastic will begin to cool instantly.

PAGE 31
STEP 06: ALLOW TO COOL STEP 07: REPEAT

PAGE 32
Once all of the air has been removed from This process can be repeated to produce many
under the plastic and it has been formed over of your desired product.
your mold, remove the formed part and set it If you notice that over time your 3D printed
aside to cool. mold becomes deformed due to heat or
pressure, it might be time to print another.

PART 3: VACUUM FORM USING 3D PRINTED MOLDS

TIP: The mold is not removed from the machine TIP: The mold is not removed from the machine
between shots between shots

STEP 08: POST PROCESSING

After you have produced the desired number of parts, cut away any spare plastic.

MAKERBOT POST-PROCESSING GUIDE

TIP: You can cut away spare plastic using a manual cutting tool, or with a CNC. If you’re using a CNC, 3D printing is
a good solution for creating custom fixtures.
 FINAL PART
MAKERBOT POST-PROCESSING GUIDE

Here, you can see what successfully vacuum formed plastic sheets look like.
PART 3: VACUUM FORM USING 3D PRINTED MOLDS
PAGE 33

Special thanks to our friends at COMCO Plastics for all their help.
 A Manufacturing Workstation.
Print Real ABS at 100ºC。 Powered by
 PROJECT 01: CLOUD T YPES AND DISPL AY STANDS

Forget tinkering and headaches. From manufacturing tools and functional prototypes
to end-use parts, only MakerBot 3D printers free professionals to focus on what matters
most: getting designs out the door quickly and at the lowest cost for maximum ROI.

Learn more at makerbot.com/professionals