A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

A thermoforming apparatus is described herein. The apparatus may include a pressure mechanism, a thermal device, a plurality of individually actuatable pins, and/or a pin actuation mechanism. The pressure mechanism may create a force against a die surface. The thermal device may change a thermal state of a material forced by the pressure mechanism against the die surface. The plurality of individually actuatable pins may form the die surface. The pin actuation mechanism may be connected to the plurality of actuatable pins and/or may actuate the pins. This apparatus improves on prior solutions in many ways. For example, embodiments of the thermoforming apparatus may require significantly less time between different molds than previous thermoforming machines and 3D printers.

A thermoforming apparatus is described herein. The apparatus may include a pressure mechanism, a thermal device, a plurality of individually actuatable pins, and/or a pin actuation mechanism. The pressure mechanism may create a force against a die surface. The thermal device may change a thermal state of a material forced by the pressure mechanism against the die surface. The plurality of individually actuatable pins may form the die surface. The pin actuation mechanism may be connected to the plurality of actuatable pins and/or may actuate the pins. This apparatus improves on prior solutions in many ways. For example, embodiments of the thermoforming apparatus may require significantly less time between different molds than previous thermoforming machines and 3D printers.

Systems and methods for providing heat to a three-dimensional article are disclosed. The method can include inserting at least a portion of the article over a form. The method can further include inserting the form and article at least partially within an article container and moving the form and article into engagement with a flexible membrane where the membrane and the article container form an airtight chamber. The method can further include exposing the airtight chamber to a pressure less than atmospheric pressure to pull the membrane against at least a portion of the article and exposing the membrane to a heated deformable media.

Systems and methods for providing heat to a three-dimensional article are disclosed. The method can include inserting at least a portion of the article over a form. The method can further include inserting the form and article at least partially within an article container and moving the form and article into engagement with a flexible membrane where the membrane and the article container form an airtight chamber. The method can further include exposing the airtight chamber to a pressure less than atmospheric pressure to pull the membrane against at least a portion of the article and exposing the membrane to a heated deformable media.

A vacuum plastic molding machine includes a heating device, a plurality of upright posts, a carrier assembly, and a demolding mechanism. The carrier assembly includes an upper carrier and a lower carrier. The upper carrier includes an upper frame, multiple upper movement structures, at least one rotation plate, at least one driving member, and at least one linking mechanism. An adjusting space is defined between the at least one rotation plate and the at least one linking mechanism. The lower carrier includes a lower frame, multiple lower movement structures, and at least one locking tenon. The locking tenon is placed into the adjusting space. The at least one driving member is rotated to change the position of the at least one locking tenon in the adjusting space, and to adjust the distance between the upper carrier and the lower carrier.

A vacuum plastic molding machine includes a heating device, a plurality of upright posts, a carrier assembly, and a demolding mechanism. The carrier assembly includes an upper carrier and a lower carrier. The upper carrier includes an upper frame, multiple upper movement structures, at least one rotation plate, at least one driving member, and at least one linking mechanism. An adjusting space is defined between the at least one rotation plate and the at least one linking mechanism. The lower carrier includes a lower frame, multiple lower movement structures, and at least one locking tenon. The locking tenon is placed into the adjusting space. The at least one driving member is rotated to change the position of the at least one locking tenon in the adjusting space, and to adjust the distance between the upper carrier and the lower carrier.

A method of forming an orthodontic aligner from an aligner digital model, the method comprising the steps of: (a) three-dimensionally printing an intermediate structure comprising fused filaments from a biocompatible thermoplastic according to the aligner digital model via fused deposition modelling; (b) coating the intermediate structure with a biocompatible translucent photopolymer; and (c) irradiating the coating with ultraviolet light to cure the coating on the intermediate structure, thereby forming the orthodontic aligner.

A thermoforming device includes two conveying units, a heating unit, a heat treatment unit and a forming unit. The conveying units define a clamp space and are adapted to move a raw material in a conveying direction. The heating unit is disposed at one side of the clamp space along a first axis, and includes a plurality of heating subunits adapted for heating the raw material. The heat treatment unit abuts against the heating base, and includes a plurality of temperature control subunits adapted for adjusting the temperature of the raw material. The forming unit is disposed proximate to the heat treatment unit and is adapted for forming the shape of the raw material.