3D Systems’ Pellet 3D Printing Reshapes Thermoforming at Duo Form

Featured Sponsor Content

For thermoforming manufacturers like Duo Form, reducing production costs and lead times has become essential to staying competitive.

Traditionally, Duo Form relied on CNC machining to produce molds from ceramic or metal materials—a time-consuming, rigid, and expensive process. Each new mold required significant investment and waiting periods, limiting Duo Form’s flexibility in responding to customer demands.
Moreover, the ability to deliver rapid prototypes often made the difference between winning or losing critical business opportunities.

You can also read: Why Carbon Fiber Reinforcement Works—or Doesn’t—in 3D Printing.

As the market demanded faster innovation cycles and greater design agility, Duo Form recognized the need for a new approach to support speed, customization, and quality without prohibitive cost increases.

Embracing Pellet-Extrusion 3D Printing

Duo Form adopted large-format pellet-extrusion additive manufacturing to overcome production challenges, utilizing the EXT 1270 Titan Printer from 3D Systems.

Because this method uses low-cost thermoplastic pellets, it significantly reduces material expenses and also increases print speed by up to tenfold. This technology enables faster, cost-effective production without sacrificing mold quality or dimensional accuracy for thermoforming applications. Moreover, Duo Form selected fiber-filled polycarbonate pellets, providing the high heat resistance and dimensional stability needed for durable mold production. The porous molds produced by this technology allowed the company to produce molds faster while minimizing the need for drilling vacuum holes, typically a labor-intensive step. Consequently, Duo Form eliminated many traditional post-processing steps and tooling modifications, streamlining overall production and reducing operational complexity.

From Prototypes to Production-Ready Tools

Beyond making production molds, Duo Form strategically leveraged its 3D printing capability to accelerate design validation. Rather than waiting for full mold production, the company could now print full-scale sample parts for customer review. This advancement dramatically shortened design cycles, enabling clients to visualize, evaluate, and approve designs early in the project timeline.

By offering tangible prototypes quickly, the company enhanced its customer service, reduced risks of design errors, and positioned itself as a more responsive partner. The ability to prototype and pivot during early project stages became a competitive differentiator in securing new contracts.

Reflecting on the impact of the EXT 1270 Titan Pellet 3D Printer, David Rheinheimer, Product Development Manager at Duo Form, stated:

“We have gained a lot of business with our EXT 1270 Titan Pellet 3D Printer. The turnaround time for parts, molds, and formed parts has put us leaps and bounds above our competition.”

Tangible Results: Speed, Savings, and New Opportunities

Since adopting additive manufacturing, Duo Form has reduced mold production times and lowered overall costs across multiple industrial thermoforming projects. Because these savings extend beyond materials and labor, faster turnaround times have created more business opportunities and strengthened customer loyalty. Moreover, additive manufacturing introduced digital mold storage, allowing Duo Form to minimize physical inventory and simplify its production workflow. Rather than keeping physical molds for each part, Duo Form now archives digital files and prints replacements or updates on demand.

Consequently, the company reduced warehouse space needs and lowered inventory management costs significantly across multiple divisions and product categories. Importantly, Duo Form did not eliminate traditional machining but implemented a hybrid strategy combining CNC and additive methods. Duo Form strategically balances precision, speed, and production cost based on project needs by blending additive printing with conventional CNC techniques.