3D printing service – online and fast
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Has been building for a few years Igus the division for additive manufacturing with 3D Print, Filamentdevelopment & co. Brand new are a new one Lifetime Calculator for 3D printing parts and there is a 3D printing service for XXL parts up to 3 m in size. With 4K for 3D, the Cologne company offers one Multi-material printing for multifunctional components. These and all other innovations in additive manufacturing at igus can be found below:
Contents
- Igus 3D printing news
- Calculate lifetime of 3D printed parts in 30 s
- 3D printing service for components up to 3 m in size
- Four components additive manufacturing process
- Print stable and abrasion-resistant components yourself
- Iglidur I190 beats standard plastics by a large margin
- 3D printing in space with Igus linear axes
- Additive manufacturing for predictive maintenance
- Design freedom in the automotive industry
- Injected like printed - 3D printing in a new dimension
- 3D printed injection molding tools for series up to 500 pieces
Igus 3D printing news
Additive manufacturing offers practically unlimited possibilities, also at igus. And the Cologne plastics specialists are a forge of innovation. We present them to you here New Products from the 3D printing area of the company:
Calculate lifetime of 3D printed parts in 30 s
21.07.2023/XNUMX/XNUMX | If you die required durability of a 3D-printed component, this often makes it easier to select the optimal material. That's why Igus has his 3D printing service expanded. In addition to feasibility studies and price calculations, the online 3D printing service can now also predict the service life of customer-specific special parts in just a few seconds. To do this, the user simply uploads the STEP or STL file, calculates the service life, selects the appropriate material and adds it to the shopping cart. The ordered part will be shipped within three days.
After uploading the 3D file, this is determined online Tool the manufacturing options, suitable materials and finishes and shows costs, feasibility and delivery time. "We have now integrated the service life calculation into the 3D printing service. Because knowing the longevity of a component in advance makes it easier to decide on the right material, in addition to price information,” explains Tom Krause, Business Unit Manager Additive Manufacturing. And how does the calculation work? “To do this, the user simply has to select the sliding surface of his part with a mouse click and enter a few application parameters. The 3D printing service then automatically calculates a service life estimate".
Igus exhibits at the EMO 2023.
3D printing service for components up to 3 m in size
07.09.2021 | Igus now prints lubrication-free and maintenance-free plastic components that can be up to 3 m in size in just one printing process. The lightweight Tribo components are up to 50 times more abrasion resistant as standard plastics. The XXL components produced in additive manufacturing are best suited for cost-saving use in large machine construction, especially in fixture construction, special machine construction or packaging technology. In direct comparison to machining, the rapid manufacturing components impress with their lightweight design, greatly reduced material requirements and shorter production times of 80% each.
Filaments according to EU regulation and FDA
When manufacturing the large-format parts from 3D printing, igus relies in particular on the tribofilaments iglidur I150 and the optically detectable blue variant iglidur I151. This allows lubrication-free special parts for the movement to be manufactured quickly and inexpensively. The plastics are after EU Regulation 10 / 2011 for the Food industry Iglidur I151 is also certified FDA compliant.
Material and filament for 3D printing
Both filaments can be used on any 3D printer that has the Nozzle temperature to 250 ° C can be adjusted. Because the shrinkage of these high-performance plastics is very low, they can also be processed on 3D printers without a heated printing plate. The wear resistance is very high at sliding speeds of up to 0,2 m/s. The iglidur I150 and iglidur I151 are available on large 8 kg filament rolls. The materials are therefore particularly suitable for the production of large components in large-capacity printers. Igus offers a 3D printing service for the XXL parts. For additive manufacturing, data is simply uploaded online, the material is selected, the prices are calculated and the individual XXL wear part is ordered directly.
Four components additive manufacturing process
15.04.2021/3/XNUMX | The XNUMXD printing of individual wear parts with different materials offers designers great design options and such multifunctional components significantly reduce the manufacturing process. However, if a component is to have several properties, it usually has to be manufactured in several manufacturing processes. This can quickly become expensive with small quantities.
Multi-material printing from 4 materials
Igus has been offering the additive manufacturing of durable special parts in multi-material printing with two materials since 2020. In this way, wear-resistant and resilient components as well as intelligent special parts can be produced. Now the company has expanded the service and offers the Multi-material 3D printing with up to four Materials at. In the 3D printing process the production of multifunctional and wear-resistant components in just one step is cost-effective and quick. For this rapid prototyping, the Cologne-based company has further expanded its 3D printing capacities and its range of materials for the FDM (Fused Deposition Modeling) manufacturing process.
"To this end, we have expanded our 3D printing production and are now also offering new materials that can be specially processed in multi-material printing," explains Tom Krause, Head of the Additive Manufacturing division at Igus GmbH. "For example, we can manufacture parts for fixture, tool or special machine construction inexpensively from a quantity of 1 in a few days."
Print 3D service for bearings that are 50 times more abrasion-resistant
The materials for additive manufacturing with multi-material have different properties. Components made with Iglidur tribofilaments enjoy low-friction, maintenance-free and up to 50 times more abrasion-resistant components than they could be made with regular 3D printing materials. iglidur I160-EL is a new elastic material that can be used, for example, as a seal in the individual Warehouse can be printed. Igumid P150 is the new 3D printing filament for multi-material printing, which ensures a high flexural strength of 87 MPa for the components.
Especially for the additive manufacturing of intelligent Components with integrated sensors there are two other smart materials: Sigumid P and Sigumid F. The latter is pressed into the bearing and gives a signal via a break contact when the wear limit has been reached. Sigumid P, on the other hand, warns of an overload of the bearing, because the shape and thus the resistance change when pressure is applied to the bearing. "Through the 4K 3D printing All the properties of the different materials such as wear resistance, stability, elasticity and intelligence can now be combined in complex components, ”summarizes Tom Krause.
Lecture at the Formnext trade fair
Print stable and abrasion-resistant components yourself
22.02.2021/3/XNUMX | In order to be able to produce wearing parts in special dimensions quickly and inexpensively, more and more companies are resorting to additive manufacturing using XNUMXD printing. Now Igus has with me Iglidur I190 developed an easy-to-use all-rounder filament. It offers a high mechanical flexural strength of 80 MPa. "Iglidur I190 is characterized above all by its high strength, so that even filigree structures in the printed component are stable," explains Tom Krause. Because the tribologically optimized material combines very well with highly rigid materials, Iglidur I190 is also suitable for the construction of sliding components for multi-material components. The lubricant-free filament can be easily processed on all commercially available closed 3D printers with a heatable printing plate at temperatures of up to 90 ° C.
Iglidur I190 beats standard plastics by a large margin
22.02.2021 | In a test The iglidur I3800 has proven its longevity in its own 190 m² laboratory. A 3D-printed iglidur I190 plain bearing competed against additively manufactured bearings made of ABS and polyamide as well as turned and injected bearings made of POM and nylon.
As a result, the printed Igus stock was up to 50 times more abrasion resistant than the standard plastic bearings. Even in the internal competition, Iglidur I190 won with 80 to 46 MPa against the food-compliant Iglidur I150 filament in terms of flexural strength.
Eleven materials for the SLS 3D design
A total of eight Filaments is currently offered by igus for the FDM and three high-performance polymers for the SLS process. The user can either order the material and process it on his printer himself, or use the manufacturer's 3D printing service. To do this, he uploads the STEP file for his component to the shop, selects the material and desired quantity and orders. Delivery takes place within three to five days.
3D printing in space with Igus linear axes
09.02.2021 | If booms for satellite antennas or solar panels are transported into space in a launch vehicle, they are exposed to high loads. That Student team Aimis-FYT is working on a 3D printing process as part of her aerospace engineering course in order to simplify the complex transport and accelerate the production of the elements. structural parts are to be produced directly in space. The students have one for experimental tests in weightlessness 3D printer built. The maintenance-free and lightweight Drylin SAWlinear axes put the Drive Technology.
Photoreactive resin and UV light
In their project, the students rely on photoreactive resin and UV light to harden the resin. For experimental tests of the procedure in weightlessness one had to 3D printer designed and built. When looking for the right drive technology, the engineers turned to the Motion Plastics specialist.
You were with the Drylin SAW linear axes find it. The linear modules are used in the two Z-axes and in the X-axis of the printer. They form the central drive unit. The linear axes are very light because they are made of aluminum and the maintenance-free sliding elements are made of high-performance plastic. To play the lubricant-free and dirt-resistant polymer Linear slider To reduce this, the budding engineers used adjustable bearings. A compact one was used to rotate the print thread Robolink D axis of rotation with worm gear built into the printer.
Successful series of tests under real conditions
To test the printer and process, the team applied for the Fly your Thesis! Program the European Space Agency (ESA) and received the approval. The parabolic flights took place at the end of last year. Once the aircraft has peaked its climb and begins to descend, microgravity similar to weightlessness in space occurs. These are ideal conditions for a real test of the printer. "The linear axes always ran without any problems in all experiments, so that we were able to print a small rod and also small truss structures for each parabola," says a pleased Torben Shepherd from the Aimis-FYT team.
Additive manufacturing for predictive maintenance
18.11.2020 | 3D printing wear parts from additive manufacturing at Igus already often offer the same service life as original parts. Now the Motion Plastics specialist is going one step further: Printed directly into the component sensors makes the printed Plastic components intelligently. Manufactured using filament printing, they warn of overload and report the need for maintenance. The engineers at igus have succeeded in combining additive manufacturing and Industry 4.0 in just one production step: Per Multi-material printing the sensor system is integrated into the additively manufactured tribo component for the first time.
The whole world of igus robots
"With the smart 3D printed warehouse we have now made a real breakthrough," says Tom Krause, Head of Additive Manufacturing at igus. "In this way, additive manufacturing makes cost-effective predictive maintenance possible, even for special parts." Long before a failure, the smart 3D-printed warehouse reports that a replacement is imminent. It detects overload and stops the application. This prevents further damage to the storage location and the entire system. Since 2016, igus has been producing intelligent wearing parts in additive manufacturing such as bearings, linear guideand Energy chain. Initially, one made plain bearings in the laser sintering process Iglidur I3 and the intelligence is then introduced in a second processing step.
Thomas Krause presents the world first
The production intelligent special parts with the small quantities, however, is complex and expensive because the subsequent work steps are designed very specifically for the respective 3D printed component. With a new process, the developers can now produce such intelligent wearing parts in just one step. Further processing steps are omitted. Intelligent special wear parts can be manufactured cost-effectively from five working days. The sensor layer is applied to the parts of the component that are to be subjected to stress. On the basis of multi-material printing, wear-resistant components with integrated sensors are created. The components are made up of the filaments Iglidur I150 or I180 and a specially developed electrically conductive 3D printing material. This connects very well with the tribofilament.
Possibilities of the smart 3D printing process
Currently are two applications possible: The electrically conductive material warns of overload if it is located between the layers subject to wear. Because if the load changes, the electrical resistance also changes. The machine can be stopped. Further damage can be prevented. To determine the load limits, the bearing must be calibrated accordingly.
If, on the other hand, the conductor track was introduced into the sliding surface, the wear can be measured via the change in resistance. With this 3D printing component Predictive Maintenance or predictive maintenance possible. The lubrication-free and maintenance-free tribo component indicates its replacement. In this way, system downtimes can be avoided and maintenance planned. If you put the 3D-printed components in the Pre-production stage a, the wear or load data provide information in advance about the service life of the component or the planned application in series. Adjustments and optimizations in the development process can be implemented more easily.
Design freedom in the automotive industry
10.09.2019/XNUMX/XNUMX | Are more efficient for development Vehiclecomponents Light and durable wearing parts are required, igus offers the right answer with its 3D printing service. The user can online within few seconds commission his special part made of tribologically optimized plastics. There is a choice of over 55 lubricant-free iglidur materials.
The extended 3D printing service of the Motion Plastics specialist is particularly suitable for the short-term production of wearing parts. The solutions are made from the highly wear-resistant "iglidur" tribo-polymers. Tests in the laboratory show that they are up to 50 times more abrasion-resistant than standard plastics and can keep up with molded parts in terms of wear resistance. The printed consumables are also light and quiet in motion – important criteria for vehicle construction. Printed solutions are already being used, for example, in turbochargers, as pivot bearings in wheel carriers or for mounting a gas ring in special vehicle construction.
Spoiled for choice in manufacturing processes
The user has a free choice of different manufacturing processes in the 3D printing service: He can have his component manufactured in the SLS process with the tribo-plastics iglidur I3, iglidur I6 or alternatively using seven different filaments in the FDM process. The manufacturer also offers this so that the individual component consists of the optimal iglidur material for the respective application Print2Mould process at. For this purpose, an injection molding tool for the special solution is 3D printed and then inserted into the injection molding machine. The user can thus freely choose from the iglidur range of materials with its 55 tribo-polymers.
Kettcar for adults creates a range of up to 200 km
The way to lubricant-free special solution is very simple: call up the 3D printing service, upload the step file for the component and select the right material. The price for production (with the Print2Mould process including the costs for the injection molding tool) as well as information on the material, precision and flexural strength are directly visible online. After selecting the appropriate tribo-plastic, the user can enter the quantity and directly request an offer or place an order. The additively manufactured special solutions can be delivered after just 3 to 5 days. In the case of the Print2Mould process, the injected solutions are ready for dispatch after 10 working days.
Injected like printed - 3D printing in a new dimension
01.02.2017 | Tom Krause, Product Manager Iglidur Tribo-Filament, Igus GmbH, Cologne, presents 3D printing in a new dimension, with which the company can provide individual wearing parts within 24 hours. The lecture was held on the occasion of the trade press days in Bruchsal.
3D printed injection molding tools for series up to 500 pieces
13.10.2016 | Injection molding is an efficient method when it comes to the series production of high-performance plastics for moving application goes. The injection molding tools required for this are mostly made of steel and only pay for themselves with large quantities. With the first 500D-printed injection molding tool, igus has now developed a cost-saving alternative for series of up to 3 pieces.
As a injection molded part Injected, milled from a semi-finished product or printed in additive manufacturing: The plastics specialist offers users a wide range of options for obtaining their desired form of lubrication-free and maintenance-free plastic plain bearings quickly and inexpensively. Each production method has its own advantages: While injection molding can be used to produce large quantities of any iglidur material, cheaper special shapes are possible with semi-finished products. Additive manufacturing can be used cost-effectively smaller series produce with special iglidur 3D printing materials. The motion plastics specialist has now combined two of the processes in order to offer the customer freedom in the choice of material on the one hand, and on the other hand to enable special shapes in larger quantities.
Customer-specific injection molds made of high-performance plastics can now be realized in a short time. With the SLS procedure can be produced in the appropriate tool and used directly in the injection molding machine. The prerequisite is that the molded parts are simple geometries. When it comes to injection molded parts, the customer has a large selection of tribologically optimized materials from the iglidur range that can be calculated online: from chemical and temperature-resistant to particularly resilient to universally applicable high-performance plastics for movement.
With the printed tools specific special parts can also be manufactured quickly and cheaply in larger quantities for individual environmental conditions. This results in clear advantages, especially in the test phase. Because users who want to test samples for the later series often face the challenge with semi-finished or 3D-printed products that these parts differ significantly from the series part. Therefore, the final endurance test is often carried out with injected parts. Due to the injection mold produced using the 3D printing process, the special part is particularly close to the series product in the test phase, while costs are significantly reduced at the same time.
Igus 3D printing service
Where does the igus 3D printing know-how come from?
The data for all service life calculators are based on the extensive test series in the Cologne-based company's large laboratory. Annually on 450 test centers 11.000 abrasion tests driven. These show that the 3D printed parts made from iglidur plain bearing plastics are in no way inferior to the injection-moulded and turned machine elements made from conventional plastics. The service life, on the other hand, is up to 10 times longer. And it gets even better: Compared to other 3D printing materials, an iglidur 3D print offers a service life that is up to 50 times longer. More than 50 iglidur materials for injection molding, four SLS materials, 10 tribofilaments and the new iglidur Resin i3000 for 3D printing leave almost nothing to be desired.
What offers does the igus 3D printing service offer?
- Do you have a 3D model of your future component and would you like to have prototypes made of it in up to 3 days?
- Are you looking for wear-resistant materials that can be SLS, FDM or DLP printed?
- Would you like to individually configure various designs of a 3D model?
Then you are exactly right with the online 3D printing service from igus! From individual parts to small series the plastics specialist prints the right special parts from abrasion-resistant plastics using different processes and materials such as filament, laser sintering powder, liquid resins or with the help of rapid tooling. These offer up to 50 times more durability than conventional materials. You can also convince yourself of the quality of the 3D print, the material or the products in advance by ordering a free sample. Free webinars also provide you with the igus know-how. Igus even offers help for private individuals who need items such as spare parts.
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Angela Struck is editor-in-chief of the development scout and freelance journalist as well as managing director of Presse Service Büro GbR in Ried.