An industrial equipment manufacturer came to us with an enclosure design that had been developed on solid modeling software by an engineer whose previous experience was almost entirely in machined components. The geometry was clean, internal ribs for stiffness, a tight-tolerance bore for a sensor interface, undercut features along two edges, and a cosmetic exterior face with a specified surface finish. On screen it looked exactly like what the customer needed.
The problem emerged when the design hit the sheet metal shop. The ribs could not be formed. They required a fabricated assembly of welded reinforcements that tripled the labor estimate. The undercuts were not reproducible in flat-formed sheet metal without a multi-piece fabricated assembly that the design had not accounted for. The tight-tolerance bore required a separate machined insert because sheet metal cannot hold bore tolerances. And the cosmetic exterior needed powder coating over formed surfaces that carried tool marks the finish could not fully hide.
The design was not wrong for sheet metal because the engineer made mistakes. It was wrong for sheet metal because it had been designed with solid modeling instincts applied to a process that operates on fundamentally different logic. Sheet metal, vacuum forming, and metal casting each have their own physics, and a geometry that works cleanly in one process can be impractical, expensive, or impossible in another.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
| Material | Mechanical Properties | Physical Properties | Chemical Properties | Features | Common Applications |
|---|---|---|---|---|---|
|
Tensile Strength: 60-70 MPa Impact Strength: 10-20 kJ/m² Heat Deflection Temperature: 135-150°C |
Transparent or translucent Good dimensional stability |
Resistant to many chemicals and oils
|
Excellent transparency High temperature resistance |
Aerospace and Defense: Transparent canopies, Medical: Medical device components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Heat Deflection Temperature: 100-120°C |
Various colors available Good dimensional stability |
Resistant to many chemicals and oils
|
Suitable for high-temperature applications |
Aerospace and Defense: Engine components, Automotive: Engine components |
|
|
Tensile Strength: 60-80 MPa Impact Strength: 20-40 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Various colors available Low density Good dimensional stability |
Resistant to many chemicals and oils
|
High strength and impact resistance Lightweight |
Automotive: Bumpers, Aerospace and Defense: Structural components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Black color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
Black appearance
Lightweight – Durable |
Consumer Products: Electronics casings, automotive interior parts |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
White color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
White appearance
Lightweight Durable |
Consumer Products: Electronics casings, toys, kitchen appliances |
|
|
ABS |
Good impact resistance |
Density: 1.03 g/cm³ |
Resistant to diluted acids, alkalis |
High strength, versatility,
cost-effective |
Automotive, Consumer Products |
|
ABS – M30i |
– Good tensile strength |
– Density: 1.04 g/cm³ |
– Medical grade |
– Biocompatible, sterilizable, suitable for medical devices |
Medical |
|
ABS ESD |
– Static-dissipative properties |
– Density: 1.06 g/cm³ |
– ESD protection |
– Prevents electrostatic discharge, suitable for electronics |
Aerospace and Defense, Consumer Products |
|
ABS-Like |
– High toughness and durability |
– Density: Varies by formulation |
– Resistant to various chemicals |
– Resembles ABS but may offer specific improvements |
Varies by formulation |
|
Accura 25 |
– High accuracy and resolution |
– Density: Varies by formulation |
– Photopolymer |
– Used in stereolithography 3D printing, fine details |
Consumer Products, Medical, Aerospace and Defense |
|
Accura 60 |
– High strength and durability |
– Density: Varies by formulation |
– Photopolymer |
– Tough and durable, suitable for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura AMX Rigid Black |
– High impact resistance |
– Density: Varies by formulation |
– Photopolymer |
– Rigid and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura ClearVue |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Crystal clear appearance, ideal for clear parts |
Consumer Products, Medical |
|
Accura Xtreme Grey/White |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Resistant to high temperatures, strong and rigid |
Consumer Products, Aerospace and Defense |
|
ASA |
– Excellent UV resistance |
– Density: 1.07 g/cm³ |
– Weather-resistant |
– Outdoor durability, retains color and strength in sunlight |
Automotive, Consumer Products |
|
Nylon |
– High tensile strength |
– Density: 1.15 g/cm³ |
– Resistant to moisture, chemicals |
– Tough and durable, suitable for functional parts |
Aerospace and Defense, Automotive, Consumer Products |
|
Nylon 11 Flame Retardant |
– Flame retardant properties |
– Density: Varies by formulation |
– Flame-resistant |
– Fire safety, suitable for applications requiring flame resistance |
Aerospace and Defense, Automotive |
|
Nylon 12 |
– Good chemical resistance |
– Density: 1.02 g/cm³ |
– Resistant to oils, greases |
– Versatile, suitable for various industrial applications |
Aerospace and Defense, Automotive, Consumer Products, Oil and Gas |
|
Nylon 6 |
– High impact strength |
– Density: 1.14 g/cm³ |
– Resistant to moisture, abrasion |
– Durable, excellent for applications requiring impact resistance |
Automotive, Consumer Products |
|
PA 12 Glass Beads |
– Improved stiffness and dimensional stability |
– Density: Varies by formulation |
– Reinforced with glass beads |
– Increased stiffness, suitable for engineering applications |
Automotive, Aerospace and Defense |
|
PC-ISO |
– High strength and heat resistance |
– Density: Varies by formulation |
– Biocompatible |
– Suitable for medical and aerospace applications |
Aerospace and Defense, Medical |
|
PC+ABS |
– Good impact resistance |
– Density: Varies by formulation |
– Resistant to chemicals |
– Blends properties of PC and ABS, versatile material |
Automotive, Consumer Products |
|
PETG |
– Excellent transparency and impact resistance |
– Density: 1.27 g/cm³ |
– Food-safe, BPA-free |
– Clarity and toughness, ideal for packaging and displays |
Consumer Products, Medical |
|
PLA |
– Biodegradable and easy to print |
– Density: 1.24 g/cm³ |
– Biodegradable |
– Eco-friendly, easy to 3D print |
Consumer Products, Medical |
|
Polycarbonate (PC) |
– High impact resistance, optical clarity |
– Density: 1.20 g/cm³ |
– Excellent optical properties |
– Exceptional clarity and strength, suitable for transparent parts |
Aerospace and Defense, Consumer Products, Medical |
|
Polypropylene |
– Low density and good chemical resistance |
– Density: 0.90 g/cm³ |
– Resistant to moisture, chemicals |
– Lightweight, suitable for low-stress applications |
Consumer Products, Automotive |
|
Rubber-Like |
– Flexible and rubber-like properties |
– Density: Varies by formulation |
– Flexible elastomer |
– Mimics rubber, suitable for gaskets and seals |
Automotive, Consumer Products |
|
Somos Evolve |
– High strength and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Engineering-grade material, suitable for functional prototypes |
Aerospace and Defense, Automotive |
|
Somos PerFORM |
– High stiffness and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Strong and stiff, ideal for high-temperature applications |
Aerospace and Defense |
|
Somos Waterclear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent, suitable for clear prototypes and parts |
Consumer Products, Medical |
|
Somos Watershed |
– Excellent clarity and water resistance |
– Density: Varies by formulation |
– Photopolymer |
– Waterproof, suitable for water-resistant parts |
Consumer Products, Medical |
|
ST-130 |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Rigid, tough, and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
TPU 88A |
– Flexible and elastomeric properties |
– Density: Varies by formulation |
– Thermoplastic polyurethane |
– Flexibility and resilience, suitable for elastomeric parts |
Automotive, Consumer Products, Medical |
|
Ultem 1010 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Engineering-grade thermoplastic with excellent properties |
Aerospace and Defense, Automotive, Oil and Gas |
|
Ultem 9085 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Suitable for aerospace and transportation applications |
Aerospace and Defense, Automotive |
|
Vero |
– Rigid and durable |
– Density: Varies by formulation |
– Photopolymer |
– Versatile material, good for prototypes and models |
Consumer Products, Aerospace and Defense |
|
VeroClear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent appearance, ideal for clear parts |
Consumer Products, Medical |
Sheet metal fabrication is one of the most misapplied processes in product development, not because engineers do not understand it, but because the instincts that come from solid modeling do not transfer to flat-stock fabrication the way designers assume they do.
The fundamental logic of sheet metal is this: flat material is cut, bent, and formed into three-dimensional geometry. Every feature of the finished part originates in a flat blank, and the rules that govern the transformation from flat to formed are specific, predictable, and unforgiving when ignored at the design stage.
The flat-pattern problem is where most sheet metal designs go wrong first. When sheet metal bends, the material on the outside of the bend stretches and the material on the inside compresses. Bend allowance, the calculated length of material consumed by each bend, must be accounted for in the flat pattern or the finished part will be dimensionally incorrect. CAD software calculates bend allowances automatically, but only when the correct K-factor is applied for the specific material and thickness being fabricated. Default K-factors are approximations. They do not always match real-world fabrication behavior, particularly at tight bend radii or with harder alloys.
The specific design mistakes we see repeatedly in sheet metal programs at PrintForm:
Where sheet metal earns its place without qualification: enclosures, brackets, panels, and structural frames where the geometry is genuinely suited to flat-stock fabrication. Low to medium volumes where injection molding is not economically justified. Applications requiring steel or aluminum where machining from solid would be wasteful. Secondary finishing, powder coat, anodize, paint, and hardware insertion through PEM nuts or welded studs are standard operations in sheet metal programs and should be included in cost comparisons from the beginning, not discovered after the primary fabrication quote.
Our team reviews designs across sheet metal, CNC, injection molding, additive, cast urethane, and more. We will tell you what works, what does not, and why.
Vacuum forming gets proposed for the wrong parts more often than almost any other process in manufacturing. It is fast, the tooling is inexpensive relative to injection molding, and it can produce large-format cosmetic parts at a fraction of the cost of a comparable steel mold. Those advantages are real, and they apply to a specific and fairly narrow class of geometry.
The process fundamentals: a plastic sheet is heated until pliable, draped over a tool, and pulled tight against the tool surface by vacuum pressure. The result is a thin-walled part that conforms to the exterior tool geometry on one face. The non-tool face is open and uncontrolled. Wall thickness is not uniform. It thins at corners and stretches over features as the sheet is drawn, in ways that are geometry-dependent and not always predictable without simulation.
What vacuum forming does well is unambiguous: large-format covers, housings, trays, liners, and enclosures with one cosmetic face, moderate structural requirements, and geometry that is essentially shallow. Tooling cost from aluminum, wood, or composite materials at a fraction of injection mold investment. Lead times are measured in days to two weeks rather than months.
What vacuum forming cannot do is equally unambiguous, and the list matters for anyone considering the process for a complex part:
The right question to ask before vacuum forming is on the table: is this part essentially a shell, large, relatively shallow, with one cosmetic face and modest structural demands? If the answer is yes, vacuum forming deserves serious consideration. If the answer involves ribs, bores, undercuts, or tight tolerances, the process is being proposed for a part it cannot produce faithfully, and the cost savings on tooling will be consumed by secondary operations, redesign, and parts that do not meet specification.
Tolerances, surface finish, cost curves, lead time, and feature-by-feature breakdowns. All in one place.
Metal casting covers more ground than most engineers realize when they hear the term. Sand casting, die casting, investment casting, and permanent mold casting are four genuinely different processes with different tooling costs, different dimensional capabilities, different surface finish outcomes, and different volume breakeven points. Treating them as interchangeable alternatives is a mistake that produces cost estimates and lead time expectations that do not survive contact with a real quote.
What metal casting does well as a category: complex three-dimensional metal geometry that would be prohibitively expensive to machine from solid. Material properties native to cast alloys, aluminum, zinc, magnesium, iron, and steel, that cannot be replicated in polymer processes. Integrated features that consolidate multi-part machined assemblies into a single near-net-shape casting. Medium to high volumes at competitive per-part cost once tooling is amortized.
Where each variant fits, based on what we see in practice:
The feature that requires secondary machining regardless of casting variant is the tight-tolerance bore. No casting process holds bore tolerances reliably enough to eliminate post-machining for precision applications. The material behavior during solidification introduces variation that secondary machining corrects. This is a consistent cost in metal casting programs and one that should appear in any honest comparison.
Porosity is the other characteristic that deserves direct acknowledgment. It is an inherent risk in casting processes, gas pockets and shrinkage voids that form during solidification. In structural applications, undetected porosity is a failure waiting to happen. X-ray inspection and process controls manage the risk, but they do not eliminate it, and they add cost and lead time that should be included in the comparison from the beginning.
The consistent pattern across sheet metal, vacuum forming, and metal casting programs at PrintForm is that secondary operations, the work required after the primary process to bring the part to specification, are systematically underrepresented in initial cost comparisons.
Post-machining of cast or formed parts to achieve tight tolerances on critical features. Surface finishing, powder coating, anodizing, painting, polishing, to meet cosmetic or functional requirements. Hardware installation through PEM inserts, welded studs, or heat-set fasteners to provide durable threaded interfaces that the primary material cannot reliably deliver on its own. Heat treatment to modify material properties after forming or casting.
Each of these is a real cost and a real lead time addition. A sheet metal enclosure quoted at $85 per part that requires $40 in powder coating and $15 in PEM hardware installation is a $140 part. A sand casting quoted at $120 that requires $60 in secondary machining and $25 in surface finishing is a $205 part. Quotes that do not include secondary operations are not complete quotes. They are starting points that become expensive when the full scope of work becomes visible at first article.
The teams that avoid this surprise are the ones who define secondary operations scope before requesting a quote, not after reviewing it. That requires knowing which features in the primary process will require post-processing, which is exactly the kind of process-specific knowledge that most design teams do not carry internally and should not need to build from scratch.
PrintForm brings the cross-process expertise to tell you, before you request a quote, which features in your design will require secondary operations, which process variant matches your volume and geometry, and where the cost comparison between processes actually lands when secondary work is included. We embed that knowledge into your program from the first geometry review, so the surprises stay on the drawing board where they belong.
We ran one benchmark part through eight manufacturing processes and documented every tradeoff across dimensional accuracy, surface finish, cost, and lead time. No assumptions. No generics.
Then talk to our team about applying it to your specific program.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
| Material | Mechanical Properties | Physical Properties | Chemical Properties | Features | Common Applications |
|---|---|---|---|---|---|
|
Tensile Strength: 60-70 MPa Impact Strength: 10-20 kJ/m² Heat Deflection Temperature: 135-150°C |
Transparent or translucent Good dimensional stability |
Resistant to many chemicals and oils
|
Excellent transparency High temperature resistance |
Aerospace and Defense: Transparent canopies, Medical: Medical device components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Heat Deflection Temperature: 100-120°C |
Various colors available Good dimensional stability |
Resistant to many chemicals and oils
|
Suitable for high-temperature applications |
Aerospace and Defense: Engine components, Automotive: Engine components |
|
|
Tensile Strength: 60-80 MPa Impact Strength: 20-40 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Various colors available Low density Good dimensional stability |
Resistant to many chemicals and oils
|
High strength and impact resistance Lightweight |
Automotive: Bumpers, Aerospace and Defense: Structural components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Black color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
Black appearance
Lightweight – Durable |
Consumer Products: Electronics casings, automotive interior parts |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
White color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
White appearance
Lightweight Durable |
Consumer Products: Electronics casings, toys, kitchen appliances |
|
|
ABS |
Good impact resistance |
Density: 1.03 g/cm³ |
Resistant to diluted acids, alkalis |
High strength, versatility,
cost-effective |
Automotive, Consumer Products |
|
ABS – M30i |
– Good tensile strength |
– Density: 1.04 g/cm³ |
– Medical grade |
– Biocompatible, sterilizable, suitable for medical devices |
Medical |
|
ABS ESD |
– Static-dissipative properties |
– Density: 1.06 g/cm³ |
– ESD protection |
– Prevents electrostatic discharge, suitable for electronics |
Aerospace and Defense, Consumer Products |
|
ABS-Like |
– High toughness and durability |
– Density: Varies by formulation |
– Resistant to various chemicals |
– Resembles ABS but may offer specific improvements |
Varies by formulation |
|
Accura 25 |
– High accuracy and resolution |
– Density: Varies by formulation |
– Photopolymer |
– Used in stereolithography 3D printing, fine details |
Consumer Products, Medical, Aerospace and Defense |
|
Accura 60 |
– High strength and durability |
– Density: Varies by formulation |
– Photopolymer |
– Tough and durable, suitable for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura AMX Rigid Black |
– High impact resistance |
– Density: Varies by formulation |
– Photopolymer |
– Rigid and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura ClearVue |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Crystal clear appearance, ideal for clear parts |
Consumer Products, Medical |
|
Accura Xtreme Grey/White |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Resistant to high temperatures, strong and rigid |
Consumer Products, Aerospace and Defense |
|
ASA |
– Excellent UV resistance |
– Density: 1.07 g/cm³ |
– Weather-resistant |
– Outdoor durability, retains color and strength in sunlight |
Automotive, Consumer Products |
|
Nylon |
– High tensile strength |
– Density: 1.15 g/cm³ |
– Resistant to moisture, chemicals |
– Tough and durable, suitable for functional parts |
Aerospace and Defense, Automotive, Consumer Products |
|
Nylon 11 Flame Retardant |
– Flame retardant properties |
– Density: Varies by formulation |
– Flame-resistant |
– Fire safety, suitable for applications requiring flame resistance |
Aerospace and Defense, Automotive |
|
Nylon 12 |
– Good chemical resistance |
– Density: 1.02 g/cm³ |
– Resistant to oils, greases |
– Versatile, suitable for various industrial applications |
Aerospace and Defense, Automotive, Consumer Products, Oil and Gas |
|
Nylon 6 |
– High impact strength |
– Density: 1.14 g/cm³ |
– Resistant to moisture, abrasion |
– Durable, excellent for applications requiring impact resistance |
Automotive, Consumer Products |
|
PA 12 Glass Beads |
– Improved stiffness and dimensional stability |
– Density: Varies by formulation |
– Reinforced with glass beads |
– Increased stiffness, suitable for engineering applications |
Automotive, Aerospace and Defense |
|
PC-ISO |
– High strength and heat resistance |
– Density: Varies by formulation |
– Biocompatible |
– Suitable for medical and aerospace applications |
Aerospace and Defense, Medical |
|
PC+ABS |
– Good impact resistance |
– Density: Varies by formulation |
– Resistant to chemicals |
– Blends properties of PC and ABS, versatile material |
Automotive, Consumer Products |
|
PETG |
– Excellent transparency and impact resistance |
– Density: 1.27 g/cm³ |
– Food-safe, BPA-free |
– Clarity and toughness, ideal for packaging and displays |
Consumer Products, Medical |
|
PLA |
– Biodegradable and easy to print |
– Density: 1.24 g/cm³ |
– Biodegradable |
– Eco-friendly, easy to 3D print |
Consumer Products, Medical |
|
Polycarbonate (PC) |
– High impact resistance, optical clarity |
– Density: 1.20 g/cm³ |
– Excellent optical properties |
– Exceptional clarity and strength, suitable for transparent parts |
Aerospace and Defense, Consumer Products, Medical |
|
Polypropylene |
– Low density and good chemical resistance |
– Density: 0.90 g/cm³ |
– Resistant to moisture, chemicals |
– Lightweight, suitable for low-stress applications |
Consumer Products, Automotive |
|
Rubber-Like |
– Flexible and rubber-like properties |
– Density: Varies by formulation |
– Flexible elastomer |
– Mimics rubber, suitable for gaskets and seals |
Automotive, Consumer Products |
|
Somos Evolve |
– High strength and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Engineering-grade material, suitable for functional prototypes |
Aerospace and Defense, Automotive |
|
Somos PerFORM |
– High stiffness and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Strong and stiff, ideal for high-temperature applications |
Aerospace and Defense |
|
Somos Waterclear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent, suitable for clear prototypes and parts |
Consumer Products, Medical |
|
Somos Watershed |
– Excellent clarity and water resistance |
– Density: Varies by formulation |
– Photopolymer |
– Waterproof, suitable for water-resistant parts |
Consumer Products, Medical |
|
ST-130 |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Rigid, tough, and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
TPU 88A |
– Flexible and elastomeric properties |
– Density: Varies by formulation |
– Thermoplastic polyurethane |
– Flexibility and resilience, suitable for elastomeric parts |
Automotive, Consumer Products, Medical |
|
Ultem 1010 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Engineering-grade thermoplastic with excellent properties |
Aerospace and Defense, Automotive, Oil and Gas |
|
Ultem 9085 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Suitable for aerospace and transportation applications |
Aerospace and Defense, Automotive |
|
Vero |
– Rigid and durable |
– Density: Varies by formulation |
– Photopolymer |
– Versatile material, good for prototypes and models |
Consumer Products, Aerospace and Defense |
|
VeroClear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent appearance, ideal for clear parts |
Consumer Products, Medical |
A defense contractor’s thermal management pads arrived dimensionally perfect.
The procurement team had three quotes on the table. They ranged from $0.58 to $0.91 per part at 50,000 units annually. The team chose the lowest.
Here is a pattern we see more often than we should. A program reaches production readiness, design is locked, tooling is ordered or already in-house, the supply chain is set.
An industrial equipment manufacturer came to us with an enclosure design that had been developed on solid modeling software by an engineer whose previous experience was almost entirely in machined components.
A product team was twelve weeks from a clinical submission deadline. They needed thirty units of a handheld medical device housing, production-representative in cosmetics, dimensionally accurate, and available in two colorways for user testing.
A consumer electronics company came to us with a housing part they had been machining at low volume while they waited on market validation.
Picture a part that has been through weeks of engineering review. The 3D model is solid. Wall thicknesses have been checked, tolerances have been assigned, and the geometry looks exactly the way it needs to function.
The quote came in at $12,000. The domestic option was $49,000. For a medical device manufacturer under budget pressure, the math looked obvious – until the tool arrived.
The product manager’s spreadsheet said injection molding was cheaper. It was – on a per-part basis. What the spreadsheet didn’t include was the $18,000 steel mold, the six-week lead time.
The design passed DVT. The contract manufacturer had been briefed. The steel mold was quoted. And then someone on the leadership team asked when they could start shipping.
The part passed every test. Eight months of iteration, four rounds of DVT, a signed-off design review. The first production run shipped 400 units. Thirty percent came back.
The medical device startup had 60 days to get functional housings into the hands of a clinical partner. Their enclosure design was largely validated – one or two minor tweaks still possible, but nothing structural.
A product manager at a consumer electronics company recently landed a pilot order: 1,200 units of a plastic enclosure, confirmed purchase order, ship date in eight weeks.
A medical device company completes a successful pilot. The manufacturing process looks clean, the assembly line is humming, and the launch timeline is on track – until field returns start coming in at month four.
The engineering team celebrated. Their medical device prototype worked perfectly, passed initial testing, and impressed investors. Early manufacturing decisions looked solid.
The product manager had 72 hours to decide. His startup needed 500 housings for beta units shipping to pilot customers next month.
The call came at 4 PM on a Friday. A Tier 1 automotive supplier’s injection molding resin vendor couldn’t deliver next week’s order. Force majeure.
A product manager at a medical device company got the call on a Tuesday morning. Their primary resin supplier declared force majeure. Production stopped.
A medical device startup spent eight months perfecting their prototypes. The design won awards. Investors lined up. Then they scaled to production, and the failure rate hit 40 percent.
When selecting the manufacturing process for functional prototypes or low-volume production, the decision can often feel overwhelming.
The production line was ready. Materials were in. Demand was real. Then a single tool cracked.
The first prototype looked perfect on screen. Clean geometry. Tight tolerances. Everyone nodded in the review.
In early 2020, a mid-sized molding supplier in Eastern Europe found itself in an unforeseen crisis.
In Silicon Valley, a product team racing against time had their prototype ready but something was wrong.
The part looked right on the screen. It cleared internal review. It even passed a quick Design For Manufacturing (DFM) check inside the Computer Aided Design environment.
Rapid Prototyping Is No Longer a Safety Net. It’s the Critical Path.
In the rapidly evolving healthcare and medical product development marketplace...
In the realm of modern manufacturing, CNC machining redefines precision...
The EV industry is evolving rapidly with the help of 3D printing...
Dramatic healthcare needs during COVID-19 created urgent manufacturing demand...
Getting quotes has never been more convenient...
Another successful year for PrintForm driven by customer satisfaction...
Our molding experience has grown tremendously over the years...
SLS technology is suitable for complex designs and applications...
Experience the power of PrintForm’s CNC machining services, where precision meets versatility. Our advanced manufacturing processes and skilled engineering team offer an extensive array of finish and secondary processing options. With a commitment to exceeding your expectations, we prioritize your unique requirements over any specific technology or machine. Whether it’s high-quality plastic or metal components, our CNC machining capabilities deliver unmatched dimensional accuracy, critical surface finishes, and material-specific properties. Trust PrintForm to provide precision engineering solutions that empower your success in today’s competitive landscape.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
A strong and corrosion-resistant material commonly used for CNC machining parts like precision components, medical instruments, and automotive components.
A durable thermoplastic material suitable for CNC machining complex parts like gears, bearings, and bushings, known for its excellent dimensional stability and low friction properties.
A versatile engineering plastic widely used for CNC machining components such as precision gears, rollers, and valve bodies due to its low friction, high strength, and dimensional stability.
An impact-resistant and transparent material often CNC machined into parts like safety goggles, electronic enclosures, and automotive lighting covers due to its excellent strength and optical clarity.
A strong and flexible material used for CNC machining parts like gears, pulleys, and bearings due to its high wear resistance, low friction, and excellent mechanical properties.
A durable and impact-resistant thermoplastic commonly CNC machined into parts like prototypes, enclosures, and consumer goods due to its good mechanical properties, ease of machining, and wide range of available colors.
A metal alloy known for its excellent machinability and corrosion resistance, often CNC machined into parts like fittings, valves, and decorative components due to its aesthetic appeal and durability.
A highly conductive and malleable material often CNC machined into electrical connectors, heat sinks, and RF shields due to its excellent electrical and thermal properties.
A low-carbon steel commonly CNC machined into parts like brackets, shafts, and structural components due to its strength, machinability, and cost-effectiveness.
A lightweight and versatile material used for CNC machining applications like packaging inserts, architectural models, and signage due to its ease of machining, low density, and impact-absorbing properties.
A high-performance engineering plastic known for its excellent dimensional stability, low friction, and high wear resistance, often CNC machined into parts like bushings, gears, and bearings.
| Material | Mechanical Properties | Physical Properties | Chemical Properties | Features | Common Applications |
|---|---|---|---|---|---|
|
Tensile Strength: 60-70 MPa Impact Strength: 10-20 kJ/m² Heat Deflection Temperature: 135-150°C |
Transparent or translucent Good dimensional stability |
Resistant to many chemicals and oils
|
Excellent transparency High temperature resistance |
Aerospace and Defense: Transparent canopies, Medical: Medical device components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Heat Deflection Temperature: 100-120°C |
Various colors available Good dimensional stability |
Resistant to many chemicals and oils
|
Suitable for high-temperature applications |
Aerospace and Defense: Engine components, Automotive: Engine components |
|
|
Tensile Strength: 60-80 MPa Impact Strength: 20-40 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Various colors available Low density Good dimensional stability |
Resistant to many chemicals and oils
|
High strength and impact resistance Lightweight |
Automotive: Bumpers, Aerospace and Defense: Structural components |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
Black color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
Black appearance
Lightweight – Durable |
Consumer Products: Electronics casings, automotive interior parts |
|
|
Tensile Strength: 40-60 MPa Impact Strength: 5-20 kJ/m² Density: 1.03 g/cm³ Melting Point: 220-260°C |
White color Low density Good dimensional stability |
Resistant to many chemicals and oils
|
White appearance
Lightweight Durable |
Consumer Products: Electronics casings, toys, kitchen appliances |
|
|
ABS |
Good impact resistance |
Density: 1.03 g/cm³ |
Resistant to diluted acids, alkalis |
High strength, versatility,
cost-effective |
Automotive, Consumer Products |
|
ABS – M30i |
– Good tensile strength |
– Density: 1.04 g/cm³ |
– Medical grade |
– Biocompatible, sterilizable, suitable for medical devices |
Medical |
|
ABS ESD |
– Static-dissipative properties |
– Density: 1.06 g/cm³ |
– ESD protection |
– Prevents electrostatic discharge, suitable for electronics |
Aerospace and Defense, Consumer Products |
|
ABS-Like |
– High toughness and durability |
– Density: Varies by formulation |
– Resistant to various chemicals |
– Resembles ABS but may offer specific improvements |
Varies by formulation |
|
Accura 25 |
– High accuracy and resolution |
– Density: Varies by formulation |
– Photopolymer |
– Used in stereolithography 3D printing, fine details |
Consumer Products, Medical, Aerospace and Defense |
|
Accura 60 |
– High strength and durability |
– Density: Varies by formulation |
– Photopolymer |
– Tough and durable, suitable for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura AMX Rigid Black |
– High impact resistance |
– Density: Varies by formulation |
– Photopolymer |
– Rigid and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
Accura ClearVue |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Crystal clear appearance, ideal for clear parts |
Consumer Products, Medical |
|
Accura Xtreme Grey/White |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Resistant to high temperatures, strong and rigid |
Consumer Products, Aerospace and Defense |
|
ASA |
– Excellent UV resistance |
– Density: 1.07 g/cm³ |
– Weather-resistant |
– Outdoor durability, retains color and strength in sunlight |
Automotive, Consumer Products |
|
Nylon |
– High tensile strength |
– Density: 1.15 g/cm³ |
– Resistant to moisture, chemicals |
– Tough and durable, suitable for functional parts |
Aerospace and Defense, Automotive, Consumer Products |
|
Nylon 11 Flame Retardant |
– Flame retardant properties |
– Density: Varies by formulation |
– Flame-resistant |
– Fire safety, suitable for applications requiring flame resistance |
Aerospace and Defense, Automotive |
|
Nylon 12 |
– Good chemical resistance |
– Density: 1.02 g/cm³ |
– Resistant to oils, greases |
– Versatile, suitable for various industrial applications |
Aerospace and Defense, Automotive, Consumer Products, Oil and Gas |
|
Nylon 6 |
– High impact strength |
– Density: 1.14 g/cm³ |
– Resistant to moisture, abrasion |
– Durable, excellent for applications requiring impact resistance |
Automotive, Consumer Products |
|
PA 12 Glass Beads |
– Improved stiffness and dimensional stability |
– Density: Varies by formulation |
– Reinforced with glass beads |
– Increased stiffness, suitable for engineering applications |
Automotive, Aerospace and Defense |
|
PC-ISO |
– High strength and heat resistance |
– Density: Varies by formulation |
– Biocompatible |
– Suitable for medical and aerospace applications |
Aerospace and Defense, Medical |
|
PC+ABS |
– Good impact resistance |
– Density: Varies by formulation |
– Resistant to chemicals |
– Blends properties of PC and ABS, versatile material |
Automotive, Consumer Products |
|
PETG |
– Excellent transparency and impact resistance |
– Density: 1.27 g/cm³ |
– Food-safe, BPA-free |
– Clarity and toughness, ideal for packaging and displays |
Consumer Products, Medical |
|
PLA |
– Biodegradable and easy to print |
– Density: 1.24 g/cm³ |
– Biodegradable |
– Eco-friendly, easy to 3D print |
Consumer Products, Medical |
|
Polycarbonate (PC) |
– High impact resistance, optical clarity |
– Density: 1.20 g/cm³ |
– Excellent optical properties |
– Exceptional clarity and strength, suitable for transparent parts |
Aerospace and Defense, Consumer Products, Medical |
|
Polypropylene |
– Low density and good chemical resistance |
– Density: 0.90 g/cm³ |
– Resistant to moisture, chemicals |
– Lightweight, suitable for low-stress applications |
Consumer Products, Automotive |
|
Rubber-Like |
– Flexible and rubber-like properties |
– Density: Varies by formulation |
– Flexible elastomer |
– Mimics rubber, suitable for gaskets and seals |
Automotive, Consumer Products |
|
Somos Evolve |
– High strength and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Engineering-grade material, suitable for functional prototypes |
Aerospace and Defense, Automotive |
|
Somos PerFORM |
– High stiffness and heat resistance |
– Density: Varies by formulation |
– Photopolymer |
– Strong and stiff, ideal for high-temperature applications |
Aerospace and Defense |
|
Somos Waterclear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent, suitable for clear prototypes and parts |
Consumer Products, Medical |
|
Somos Watershed |
– Excellent clarity and water resistance |
– Density: Varies by formulation |
– Photopolymer |
– Waterproof, suitable for water-resistant parts |
Consumer Products, Medical |
|
ST-130 |
– High toughness and durability |
– Density: Varies by formulation |
– Photopolymer |
– Rigid, tough, and durable, good for functional prototypes |
Consumer Products, Aerospace and Defense |
|
TPU 88A |
– Flexible and elastomeric properties |
– Density: Varies by formulation |
– Thermoplastic polyurethane |
– Flexibility and resilience, suitable for elastomeric parts |
Automotive, Consumer Products, Medical |
|
Ultem 1010 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Engineering-grade thermoplastic with excellent properties |
Aerospace and Defense, Automotive, Oil and Gas |
|
Ultem 9085 |
– High strength, heat, and chemical resistance |
– Density: 1.27 g/cm³ |
– Flame-resistant, UL 94 V0 |
– Suitable for aerospace and transportation applications |
Aerospace and Defense, Automotive |
|
Vero |
– Rigid and durable |
– Density: Varies by formulation |
– Photopolymer |
– Versatile material, good for prototypes and models |
Consumer Products, Aerospace and Defense |
|
VeroClear |
– High transparency and clarity |
– Density: Varies by formulation |
– Photopolymer |
– Transparent appearance, ideal for clear parts |
Consumer Products, Medical |
PrintForm, LLC
3423 Piedmont Rd NE, Atlanta, GA 30305, USA
:(404) 999-4916
:(404) 937-6257
: info@printform.com
