3D printing for additive manufacturing
3D printing process, 3D printer, filament or printing material, etc. for modern mechanical engineering and special industries
Image: Fraunhofer IWU
Materials + Processes | Modern, future-proof, sustainable
In the development of modern Materials and processes For industrial applications, a crucial focus is on energy saving, lightweight construction, environmental protection and sustainability. Material developers and researchers are also working on the performance and cost efficiency of new materials. And so the material Science and the Materials science a constant change. This is characterized, for example, by new steel alloys or innovative filaments for 3D printing. Of course, all of these materials also have to be processed. To do this, we will examine special process technology.
Materials and processes 2024 – The most important things in brief
In modern industry, advanced materials and innovative processes are crucial for technological progress. Examples are lightweight materials such as carbon fiber reinforced plastics (CFRP) and high-strength steels. They are in demand because they offer high strength and low weight. They are particularly widely used in the automotive and aviation industries. Bio-based plastics are becoming increasingly important to improve sustainability and ecological footprint to reduce.
On the procedure page show additive manufacturing processes, especially 3D printing, enormous leaps in development. This technology enables the production of complex and customized components with high precision and minimal material consumption. Ultrashort pulse laser technology is also innovative, enabling precise material processing and setting new standards in surface technology. This technology is used primarily in the electronics and Medical Technology used to process the finest structures and surfaces.
In the last two years, several new Materials patented, including high-temperature ceramics and nanostructured metals. These materials offer exceptional mechanical properties and open up new possibilities in areas such as aerospace, energy generation and medical technology. Nanostructured metals enable improved strength and toughness, while high-temperature ceramics can be used in extreme environments such as gas turbines and nuclear reactors.
We present some of the new products below:
Freeformer processes original plastic granules
08.10.2024 | At Fakuma 2024, Arburg's Freeformer 750-3X will produce complex functional components from a wide variety of plastic granulates in a special high-temperature version. These materials are specially certified for industries such as medical technology, electronics, mobility and aerospace.
UV protection for 3D printed components
28.09.2024/3/XNUMX | Diamant Polymer presents a solution for pore-deep impregnation of XNUMXD-printed components that offers permanent UV protection. With Dichtol AM UV Protection, additively manufactured workpieces can be effectively made gas- and liquid-tight and at the same time protected against UV radiation and discoloration.
Lubrication-free plain bearing materials without PTFE
26.09.2024/XNUMX/XNUMX | Organic fluorine compounds (PFAS) defy heat, water and dirt and help plain bearings to run dry in a wear-resistant and lubrication-free manner. However, because the chemicals break down very slowly and if they then get into the environment, this can harm people and nature. Igus is therefore developing plain bearing materials such as the new Iglidur JPF, which do not contain PFAS such as PTFE.
Openair plasma expands plastics spectrum
08.09.2024/XNUMX/XNUMX | Choosing the right plastic can have process-related, economic and ecological consequences for manufacturers, especially when it comes to adhesion properties, such as when bonding or printing. This is where Openair plasma technology comes into play as a surface pretreatment, which is crucial for the choice of material.
TSG process makes components 70% lighter
30.08.2024/XNUMX/XNUMX | Fried's TSG process combines the advantages of metal casting with those of thermoplastic injection molding. Despite their lower weight, the components have high rigidity. This is achieved through high wall thicknesses and the TSG process. This means that precision and stability can be achieved economically with a high degree of design freedom.
Control technology for ceramic and glass kilns
01.08.2024/15/XNUMX | If you are as passionate about your calling as Rohde is, it is not just a metaphor. The family-run company in Chiemgau is now one of the leading kiln manufacturers in Europe. From Ried near Prutting, it offers international customers solutions in the field of kilns and machines for ceramics and glass. Jumo has been ensuring the success of the products for XNUMX years as a close partner and supplier of control technology.
Infrared heat optimizes film processing
29.07.2024/XNUMX/XNUMX | Plastic films have a wide range of uses, such as roof sealing, food packaging or vehicle interiors. They are refined using processes such as painting, printing, embossing, laminating or covering. Such processes benefit from infrared heat. Excelitas Noblelight offers specially tailored infrared radiators for this purpose.
Antibacterial, glass fibre reinforced plastic
15.07.2024 | The Federal Association of Food Inspectors in Germany (BVLK) has officially recommended the innovative material Lamilux Antibac. This recommendation highlights the exceptional hygienic properties of the material and confirms its effectiveness in food processing.
Polyurethane solutions for the circular economy
13.07.2024/2050/XNUMX | At Utech Europe, Covestro is presenting materials and solutions that reflect the company's vision of a circular economy. Climate neutrality is a core element of this. Covestro aims to be completely climate neutral in all areas by XNUMX. Covestro is focusing on three core areas: Crafting Sustainability, Crafting Innovations and Evocycle CQ.
Groundbreaking process for the electrolysis of H2
17.06.2024 | Pajarito Powder has introduced a groundbreaking catalyst technology that dramatically changes the cost calculation for fuel cells and hydrogen electrolysis. It reduces the amount of precious metals required for reactions to generate energy from green hydrogen by up to 70%.
IR and UV emitters for high-quality car interiors
26.04.2024/XNUMX/XNUMX | Interior parts for the vehicle interior should be comfortable and user-friendly. Excelitas Noblelight has the right technology for such applications: In automobile production, an astonishing number of manufacturing steps for seats, dashboards, handles, switches, carpets and shelves are carried out efficiently with the help of infrared heat and UV lamps.
The first 100 Igus bikes hit the streets
05.03.2024 | "The igus:bike is now finally hitting the streets in a small series under a new name," says Frank Blase happily. The new branding will be announced at the Cyclingworld Europe in Düsseldorf. 100 units are currently being manufactured. After road approval, the plan is to quickly deliver the first 1200 pre-orders.
Intelligent infrared heat saves up to 80% energy
26.02.2024/XNUMX/XNUMX | Not all workpieces have flat, level contours without undercuts. Coating these, refining them or protecting them with anti-corrosion paint can be a challenge. It's good that Excelitas Noblelight's electric infrared heaters exist: They can be optimally adapted to the workpiece contour and direct the heat to the right place in precisely the right doses.
SLS printing material with 110°C temperature resistance
30.01.2024/3/110 | Igus is launching the first 230D printing material for polymer components with a temperature resistance of up to 80 °C. The new powdered material Iglidur i12 can withstand long-term use at high temperatures. In addition, the material is PTFE-free and around XNUMX% more wear-resistant than the classic PAXNUMX.
Sustainable thermoplastics digitized for automotive
24.01.2023/XNUMX/XNUMX | Sumika Polymer Compounds Europe (SPC Europe) and Hexagon Manufacturing Intelligence are working together to digitize the performance of new sustainable thermoplastics (PP) for the automotive industry. Engineers can develop recyclable components based on these thermoplastics, reducing the carbon footprint of future vehicles.
Cohesion + Adhesion: The inseparable forces
11.01.2024 | Are you wondering why water exists in droplet form or how adhesives work? The answer lies in the forces of cohesion + adhesion. In this article, you will learn what these terms mean exactly, what influence they have on everyday objects and why they are so important in nature and technology. We explain the underlying principles and show how they determine the behavior of materials.
IR camera optimizes Laser Powder Bed Fusion 3D printing
04.12.2023 | Powder bed-based laser beam melting (LPBF) allows for delicate and very complex structures and opens up ever new applications. The quality of the process depends heavily on the right temperatures. To measure these, the scientists at Fraunhofer ILT use an infrared camera from Optris.
CO2 emissions: mineral casting versus gray cast iron
29.11.2023/2/4,5 | Rampf has had the CO10 footprint of its Epument mineral cast determined. The result is an emission value that is 12.940 times lower than that of gray cast iron. For a 2-ton machine frame, for example, Epument mineral cast iron can save 360 kg of CO2 compared to gray cast iron. With around XNUMX kg of COXNUMX equivalents per ton, the material also has a clear advantage over other materials.
Coating for powder bed based laser melting
November 27.11.2023, XNUMX | Powder bed-based laser melting allows components to be manufactured more innovatively, efficiently and even more sustainably. Schaeffler Aerosint's patented Selective Powder Deposition (SPD) technology enables the application of homogeneous layers from several material areas arranged next to each other.
Thermal deburring for plastic parts
16.10.2023/2023/XNUMX | If burrs cannot be avoided in plastic molded parts, they must at least be removed easily and reproducibly, because they interfere with further processing. Heraeus Noblelight will show how this works and how modern infrared systems can be adapted precisely to the contours at Fakuma XNUMX in Friedrichshafen.
igus invests in recycling technology from Mura
09.10.2023 | Igus is investing in Mura Technology's innovative plastic recycling technology. Construction of the first large-scale plant started in April 2023 in Teesside, Great Britain. The first line with a capacity of 20.000 tons per year will go into operation this year. The first plant in Germany is also scheduled to be built in Böhlen, Saxony, by 2025.
Extremely rigid mineral casting reduces deformation
11.09.2023/80/80.000 | Durcrete, together with Dyckerhoff, has developed a special mixture for machine beds and test frames based on specially treated aggregates. The Nanodur concrete E50 has an elastic modulus of over XNUMX N/mm². This makes the material XNUMX% more deformation-stable and stiffer than the previously known classic mineral casting formulations based on epoxy resin or cement.
Material types
There are countless materials and substances that all have one thing in common today: they should be recyclable and sustainable so that they do not harm the environment. But for use in industry, metallic Materials nonmetallic Materials must be resilient, innovative, temperature-resistant, corrosion-resistant, wear-resistant and much more. We offer you an overview of innovations and the manufacturers' expertise for the most important construction materials in the following articles:
Ultra high-performance concrete for the large, heavy machine bed
Ultra high performance concrete: Rampf Machine Systems newly developed premium concrete with the name epudure is the preferred material when it comes to a large, heavy Machine bed or frame components for machines in highly dynamic mechanical engineering. These machine beds are optimized according to the requirements and in terms of casting technology.
Technical glass | Glass ceramic, acrylic glass, plexiglass
Technical glass such as glass ceramics, acrylic glass and Plexiglas play a crucial role in industrial applications. Glass ceramics impress with their temperature resistance and low expansion, while acrylic glass and Plexiglas are known for their high Transparency and breaking strength are known.
Technical ceramics | Extremely hard and temperature-resistant
Technical ceramics are characterized by their exceptional hardness, temperature resistance and chemical stability, making them ideal for demanding industrial applications. These materials offer excellent Wear and corrosion resistance and are used in areas such as Automotive engineering, medical technology and electronics.
Plastic | The alternative material plastic
The Plastics industry is booming and developing more and more new compositions such as polymers, elastomers, thermosets, thermoplastics, polystyrene and many others. The once bad reputation of plastic due to its long decomposition time is increasingly being replaced by sustainable or recycled and recyclable plastics.
Copper | Electrically and thermally conductive
Copper is a great material for Industrial Applications and Construction. The material is known for its excellent electrical and thermal conductivity. In the construction industry, copper is valued for its durability and corrosion resistance, while in the electrical industry it is wiring and components are indispensable.
Metal | Steel, Alloy & Precious Metal Materials
Metal is a fundamental material for industry, offering exceptional strength, ductility and conductivity. Steel, as the most important construction material of metals, alloys for specialized applications and Precious metals with their corrosion resistance and conductivity can be found everywhere here.
Materials + processes in practice – users report
Process engineering
Which dosing technology best distributes adhesives, how multi-material 3D printing is developing, which coating really ensures corrosion protection, how the electrolysis of hydrogen reduces the costs in fuel cell production or how production factors influence the efficiency in production: you will find out all this and much more in our articles on Process engineering.
Additive Manufacturing | Everything about 3D printing
There are several terms for 3D printing such as additive manufacturing, generative manufacturing or rapid prototyping. After the 3D Printing process initially entered prototype production, it is now well on its way to mass production. Here you will find various 3D printing innovations.
Microwave technology for 4x faster curing
The new modular microwave technology “Raku Microwave Curing” achieves ultra-fast curing and process times when mixing and dosing sealing systems, adhesives and casting compounds. The focus is on the thermal activation of one- and two-component plastic systems using microwave radiation.
E-clinching for electrical conductivity on fuse boxes
With the strong increase in e-mobility, a topic that is gaining in importance in the Automotive industry Although it has always played an important role, in practice it was played out in secret: thermal and mechanical Put or joining of sheets, assemblies and components. The E-clinching takes increasing electrification into account.
Groundbreaking process for the electrolysis of hydrogen
The groundbreaking new catalyst technology dramatically changes the cost calculation for fuel cells and hydrogen electrolysis. It reduces the amount of precious metals required for reactions to generate energy from green hydrogen needed to increase energy production by up to 70%. To implement the Varipore process Manufacturing experts are brought on board to set up large-scale production in New Mexico.
Tool and mold making | Materials and innovations
In tool and mold making, precise and efficient manufacturing technologies are required. While in Mold making Shapes and Tools While tools are manufactured for the production of components by casting, injection molding, etc., tools for processing and shaping materials are manufactured in toolmaking. The innovations of various manufacturers improve the quality of the material and shorten production times.
Dosing technology | Dosing machine and dispenser
In industrial production, precise Dosing machines and Dispenser for distributing adhesives, sealing foams and casting compounds. The latest innovations from various manufacturers show what they must be able to do in order to dispense precisely, efficiently and reliably.
Glue
Adhesives | With and without the power of nature
Adhesives are in modern Connection Technology indispensable. They offer innovative solutions for industrial production. Current developments on the market present advanced adhesives that offer increased strength, flexibility and temperature resistance. These innovations optimize production processes and enable reliable connections.
Epoxy resin | Adhesive for constructive bonding & casting
Epoxy resin adhesive, also known as epoxy glue, is used as construction adhesive which is particularly strong and resistant even under high temperatures. The connections of the 1K or 2K adhesives are vibration-resistant, oscillation-proof and shock-proof. The designer is very flexible with an epoxy resin adhesive and can also bond different materials together.
Cohesion + Adhesion: The inseparable forces
You wonder why water exists in drop form or how adhesives work? The answer lies in the forces of cohesion + adhesion. In this article, you will learn what these terms mean exactly, what influence they have on everyday objects and why they are so important in nature and technology. We explain the underlying principles and show how they determine the behavior of materials.
Industrial liquid gasket, adhesive and potting compound
There is a wide range of products for sealing and casting components. The 2-component polymer systems are based on Polyurethane, epoxy or silicone. We are leaders in mixing and dosing systems and with contract manufacturing we also offer the right service.
Cryogenic cooling reduces wear and tear and tool life
The boom in large aircraft in particular is turning the world of materials upside down: suddenly it is necessary to machine titanium, nickel-based alloys, high-strength steels and carbon fiber plastics (CFRP) on a large scale and with high productivity. Conventional cooling lubricant concepts in production often reach their physical limits here. new cooling concept is cryogenic cooling.
Laser technology | Precise cuts and markings
With laser technology, industry has precise and efficient material processing. Laser marker provide permanent markings, while Ultrashort pulse laser produce extremely fine cuts in the femtosecond range. These technologies offer high precision and flexibility, making them indispensable for a wide range of manufacturing and production applications.
Long-lasting connection between clamp body and solder pin
Weco manufactures PCB terminals with extra-long, angled or double Solder pins Manufactured at the headquarters in Hanau, the pins can be applied to a straight or angled surface. This guarantees optimal encapsulation of circuit boards with components without any restrictions. The products, which are used in heating technology, for example, offer a wide variety of variants.
Surface Technology
Coating | Surface technology for protection and aesthetics
Antibacterial, PVC, sol-gel, KTL and other Coating play a crucial role in industry by protecting materials and improving their performance. This surface technology offers corrosion protection, wear resistance and aesthetic benefits. Innovative methods such as powder coating and electroplating can make products more durable and resistant.
Openair Plasma surface pretreatment
Plasmatreat has with its Openair plasma technology an innovative surface coating for Surfacespretreatment of Plastic, Metal or Glass developed. Due to its activation power, the Openair plasma increases the surface energy significantly. Two application examples illustrate the innovative development for plasma pretreatment.
welding
Ultrasonic welding | Fast, precise, gentle on materials
When connecting from Plastics that sits down Ultrasonic welding in many industries. It is safe, efficient, energy-saving, precise, environmentally friendly, sustainable and much more. Here we present new products such as the Thermosonic bonding. Or read about how it compares to what has been predominantly used up to now heat sealing performs and how it improves the quality of the connection of critical plastic parts in the body fabricationg ensures.
Plastic welding | New products, processes, accessories
Will that be Glue from Plastic not permanently strong enough, that often happens Plastic welding as a joining process. It is used as an alternative especially for plastics that are difficult to bond, such as polypropylene PP or polyethylene PE. A welding device or a welding machine is used for this. Below we present the new developments for the thermal joining process, such as plastic welding with laser or ultrasound.
Welding | Permanently join and optimize weld seam
Welding robots are revolutionizing industrial manufacturing through precise and efficient Welding processesCurrent innovations from various manufacturers optimize the quality of the weld seam and increase productivity. Discover the latest technologies that take the efficiency and reliability of welding technology for permanent connections to a new level.
Heat processes
Infrared heaters for efficient heat processes
Infrared heater from Excelita's Noblelight play a crucial role in modern industry. With their ability to deliver heat precisely and efficiently, they optimize numerous industrial processes, from material processing until final production. Find out how Infrared Heaters Make industrial applications more efficient and of better quality and why they are considered a key technology for energy-efficient heating processes.
IR and UV emitters for high-quality properties
Should be comfortable and user-friendly Interior Parts for the Vehicle-Be interior. For such applications Excelita's Noblelight the right technology: In automobile production, an astonishing number of manufacturing steps for seats, dashboards, handles, switches, carpets and shelves are carried out with the help of Infrared-Heat and UV lamps are used efficiently.
manufacturer know-how
Exelitas Noblelight, formerly Heraeus, is known in the plastics industry for its innovative lighting solutions for plastics processing, among others. The company offers special UV lamps and IR emitters that are used in various plastics processing processes. These technologies improve efficiency and quality in applications such as curing, drying, deburring and welding of plastics.
Detailed information about the new products can be found on our partner page:
Igus manufactures a variety of high-performance plastics that have been specially developed for moving applications. The range is based on various polymers. These include: Iglidur for maintenance-free bearingsmaterials, Iglidur high-temperature plastic for extreme conditions, Iglidur FDA-compliant for the food and pharmaceutical sectors. Igus is also a manufacturer of special filaments for 3D printers, especially those developed for moving applications. A comprehensive 3D printing service is offered for this.
Detailed information about the new products can be found on our partner pages:
The special machine construction Schaeffler Group, Special Machinery, provides equipment for additive manufacturing, including multi-material 3D printing systems for unique material combinations.
Detailed information about the new products can be found on our partner page:
Frequently Asked Questions
What are material classes?
Material classes are Categories into which materials are divided based on their chemical compositions and physical properties. This classification allows engineers and technicians to select the appropriate materials for specific applications. The main classes of materials include metals, polymers, ceramics and composites.
What is the difference between materials and substances?
The difference between material and substance lies in their definition and application. material is a general term that describes any substance used to make products. This includes natural raw materials such as wood and rock, as well as synthetic substances such as plastic and metal. Materials make Materials specially selected for technical applications that must meet defined properties. Materials are therefore a subcategory of materials that are specifically developed and optimized for technical and industrial applications.
How are material groups classified in materials science?
In engineering, material groups are classified based on their physical and chemical properties and their use. The main groups of materials science are metals, polymers, ceramics and composites. This classification helps engineers select the right material for specific applications to ensure optimal performance and efficiency of the final products.