Start Production Faster with 3D Printed Sand Tooling

On-demand tooling for thermoforming, vacuum forming, or other compression tooling applications delivers molds more durable than other low-cost options that are able to withstand high temperatures, multiple hits, or even allow for full vacuum to be pulled in the forming process, all without delamination or failure.

X1 ThermoForm: Fast, Durable Tooling 3D Printed in Sand


Get tooling on demand through efficient sand 3D printing without the high costs and long lead times of traditional tools. X1 Thermoform delivers durable, low-cost tooling with fast turnarounds for short-run production or to allow production to begin while you wait for traditional tooling.

Accelerate innovation with the design freedom of additive manufacturing and eliminate the long lead times and high costs of traditional machining by creating complex tools with sand binder jet 3D printing. We use a patented process of 3D design, infiltration, and coating to produce sand forms tailored to the stability and durability requirements of a variety of tooling applications. Highly accurate, X1 ThermoForm tools can be machined to the tightest tolerances and surface finishes. 

With a low CTE that performs better than tooling board and comparable to aluminum, X1 ThermoForm tools have been tested to withstand the high temperatures of industrial production for multiple cycles. 

X1 ThermoForm tools are produced in the United States and without the waste of milling swarf or international shipping logistics. The digital
 workflow of 3D printing and domestic North American production offers customers a local, flexible, and responsive tooling supply chain.  

Infiltrated sand from ExOne is a cost-effective tooling solution with fast turnarounds. Our innovative sand binder jetting systems create unique geometries for innovative tooling that allows you to iterate quickly and test functional prototypes to improve products that get to market faster and cheaper. 


  • Rapid turnarounds with fast and cost-effective binder jet 3D printing
  • Design freedom to create streamlined geometries and incorporate mounting or venting features
  • High compression strength
  • Low Coefficient of Thermal Expansion (12 ppm/°F)
  • Durable surface coatings
  • Tolerances +/- 0.025” or better with machining
  • Service temperatures up to 300° F

Let ExOne 3D Print Your Thermoforming Tools

As a full-service tooling provider, ExOne works with customers every step of the way from tool design guidelines to printing and coating all the way through quality control.

Request a quote for x1 Thermoform
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