Thermoformed Christmas stars

Did you know that you can turn 2D decorations into 3D without additional supports? I discovered the tehcnique of thermoforming and adapted it for 3D printed parts. So I made a set of stars for my Christmas tree, using a star-shaped mold. The thermoforming process is quite simple and did not require any special equipment other than what anyone can find at home.

The set includes 2 types of star-shaped sheets with different templates. We chose gyroid and honeycomb filling for their plasticity and aesthetic effect. Below we have presented the thermoforming process.

If you want to see more shapes and enhanced version of this design explore the Christmas Bauble

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Component parts:

• star mold
• star clamp
• yellow star sheet (gyroid template)
• red star sheet (honeycomb template)

Suggestions for printing:

• Recommended to use ABS as material for clamp
• If you use PLA, it's recommended to increase infill up to 100%, to increase resistance to deformation due thermoforming process

• Settinngs for infill pattern

Suggestions for assembly:

• Use glue you want