The development of additive manufacturing processes, such as selective laser melting (SLM), has significantly extended the options for manufacturing extrusion heads. Extrusion head designs can now be realized with very slender geometries, which not only have integrated mixer functions, thereby improving the melt homogeneity, but can also be used to attach the mandrel to the head. This allows compact heads to be manufactured with a very high potential for saving operating costs. 

Improved Extrusion Head Designs thanks to Additive Manufacturing 

Additive Fertigung

Extrusionswerkzeuge

Blasformwerkzeuge

Blasformen

3D-Printed Minimalists 

Evonik Resource Efficiency GmbH, Essen, Germany, has developed a polymer powder for applications in higher temperature range as part of its polyamide 6 series. 

Temperature-Resistant PA Powder for 3D Printing 

Polyamide

Selektives Lasersintern von Kunststoff, Metall, Keramik

Thermal Properties Modified 

Additive manufacturing processes provide a very high degree of design freedom and short development times. However, the nature of the process and the limited size of build chambers restrict the size of such components. Adhesive bonding enables additively manufactured components to be joined together to form large parts. 

Increase of the Adhesive Strength by Modification of the Surfaces 

Chemisches Fügeverfahren

Advancing into New Dimensions 

A gap exists between growth in equipment sales and numbers of manufactured parts. Most likely, a lot of experimentation is still going on. A symposium provided insights into projects, problems and prospects for additive manufacturing. 

Additive Manufacturing ¿ Between Growth Euphoria and a Sense of Reality 

Fluorkunststoffe

Kunststoffverarbeitung: Maschinen und Komponenten

Putting 3D Printing to the Test 

The machine manufacturer Arburg has introduced an operating example of a digitalized AM-factory (additive manufacturing) at Hannover Messe 2019 (Hanover Fair). A turnkey system will functionalize vacuum grippers in six different versions "on demand" ¿ fully automated and 100 percent traceable. The new ATCM Scada-System simultaneously collects, visualizes, and transmits the relevant processing data. 

Fully Automated Traceable Additive Manufacturing of Small Batches and Single-Unit Parts 

Automatisierungstechnik

Industrie 4.0

Spritzgießen

Industrieroboter

Rückverfolgbarkeit, Traceability

Gripper Variants According to  Customer Requirements 

Injection is the process step in injection molding that is most quality critical. The injection speed profile and its reproducibility have a direct influence on the internal and external properties of a part. The adjustment of the injection step is therefore of particular importance. Engel injection-molding machines with electrical injection units now feature optimized setpoint computation of this profile, with clear visualization, which increases the process transparency and ease of operation. 

Improved Setpoint Calculation of the Injection Speed Profile 

Dynamic Injection ¿ Made Easy 

In order to qualify new materials for different 3D printing technologies, the company offers manufacturers of 3D printers and system providers an open materials platform. 

Henkel Wants to Qualify New Materials 

Open Materials Platform for 3D Printing 

Ford has selected desktop 3D printers to create various assembly tools, and can now produce jigs and fixtures, and even in highly complex designs, in-house at low cost. Ultimaker¿s open filament system enables the automaker to create parts with various filaments from a range of material manufacturers and meet specific material properties exactly. 

Ford Uses Additive Manufacturing with FDM Technology for Producing Assembly Tools in its Automotive Production 

Kunststoff-Halbzeuge

Printed Tools for High-Volume Production  

On the last day of the Rapid + TCT, the leading trade fair for additive manufacturing in the USA, the German machine manufacturer Arburg was honoured with the People¿s Choice Award.  

Rapid + TCT 2019: Great Success for German Machine Manufacturer 

Spritzgießmaschinen

Arburg Wins People¿s Choice Award 

Bavarian Minister of Science Bernd Sibler handing the notification of funding for the ¿FAB-Weld¿ research project to FAU Erlangen-Nürnberg, FIT and other partners  

¿FAB-Weld¿ Research Project to Investigate Welding Processes 

Vibrationsschweißen

Technik Trend

kunststoffe-international.com

Connecting SLS Parts to Injection Molded Components 

3D Printing technology may lend a hand in preventing the spread of the Coronavirus. 

Hands Free Door Opener from Materialise 

3D Printing Helps Contain the Coronavirus 

Friday, 6 March 2020 marked the opening ceremony of Arburg¿s new Training Center measuring 13,700 square metres at the company¿s headquarters in Lossburg.  

More Space, More Digitalisation, More Focus On Customers 

New Arburg Training Center 

What AM technology is considered capable of today and how it can be applied in many areas of application is shown (representative) by this expert’s view of medical technology.

To enhance the mobility of the spine, the upper and lower shell of this disc prosthesis are connected with an elastic double spring made of titanium. The core also contains a cushioning silicone filling. The prosthesis can be manufactured according to the patient’s anatomy using the LaserCusing process 

Status and Perspectives for Human Medicine

Anlagen für die Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Medizintechnik

Anlagen Additive Fertigung / 3D-Druck, Metall

Werkstoffe für additive Verfahren

Andere Werkstoffe

Medical Applications of Additive Manufacturing

Marbling is often a real eye-catcher in plastic components. However, the effect is difficult to create and there are some pitfalls when it comes to reproducibility. Novel nozzles for injection molding machines in combination with a special dosing technology allow marbled molded parts to be produced far more easily in a much more robust process.

Marbling leads to attractively designed molded plastic parts, but is not so easy to implement in production

A 3D-Printed Nozzle and Modified Dosing Method Deliver Reproducible Marbling  in a Robust Process

Kunststoffverarbeitung: Verfahren

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Kunststoffe

Photonik

Optik

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Farben, flüssig

Kunststoff Werkstoffe

Additive

Exciting Design instead of  Exciting Manufacturing

Hybrid production chains have been increasingly in the spotlight in recent years. This also applies to the combination of conventional manufacturing and additive processes in tool construction. With the example of an injection molding tool, it is shown how mold inserts produced by additive manufacturing can greatly shorten cycle times, and thereby significantly reduce unit costs. The important thing is to find a suitable combination of processes from the variety available.

Tool insert for a spacer of a glass fiber-reinforced PA66. The example shows that hybrid manufacturing is suitable and provides added value, even with comparatively simple parts

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

HSC- / HPC-Bearbeitung

Spanende Verfahren

Werkzeugkonstruktion

The Potential of Redesign and  Part Consolidation

IKV develops process for non-planar additive manufacturing with a jointed-arm robot and screw extruder.

The IKV has developed a process for non-planar additive manufacturing with jointed-arm robots and screw extruders. Compared to conventional additive manufacturing, the surface roughness can be reduced by up to 76 %.

Through the layer-by-layer production of plastic parts, additive manufacturing offers a high level of geometric freedom. Components with complex geometries and internal structures can be quickly manufactured without any set-up operations. However, these layers have until now always been planar in form and aligned parallel to the construction platform. Compared with other manufacturing technologies, layer-based processes thus have disadvantages with regard to the surface quality of the parts, caused by the step effect. Because of the lower load resistance in the build direction (attributable to the adhesion between the individual layers), the mechanical properties of the component are also anisotropic. In order to overcome these difficulties, a process for non-planar additive manufacturing with variable layer thickness was developed at IKV. With this method of path planning, it was shown that the surface roughness can be reduced by 76 % compared with conventional additive manufacturing.

With non-planar additive manufacturing, the exact form of the component and the existing load cases are taken into account when calculating the machine code. The layers generated in this way can be freely arranged in the space and can be curved. This applies both to the layers on the outer sides of the components for producing high-quality surfaces and for all layers on the inside of the component. The latter allows the specific exploitation of the technology-related anisotropy through the load path-oriented design of the individual plastic strands. The variable layer thickness, which is achieved through the specific variation of the material output, allows a gap-free transition between different curvatures and orientations.

Larger Parts, Material Variety And Accelerated Production

In order to increase the size of the part, the diversity of materials and the production rate, the implementation of non-planar path planning on a large-volume additive manufacturing screw extruder – IKV‘s hybrid production cell – is being examined in a research project. The machine‘s robot arm allows a large build volume and the use of three additional freedom levels, which are utilised to adjust the extruder according to the gradient of the component to be manufactured. In this way, the quality of the part can be further improved. In addition, the possibility exists of adjusting the load path with large-volume additively manufactured parts. By processing fibre-filled standard granules, which show very good mechanical properties in the strand direction, in combination with the specific orientation of the individual strands by non-planar additive manufacturing, the technology-related anisotropy can be exploited. This technological lead is especially relevant in the industrial application of additively manufactured parts.

IKV‘s hybrid production cell for the additive manufacturing of large-volume parts.

16:9

2022-07-27 - IKV

Additive Manufacturing at the 31st IKV Colloquium

Additive manufacturing will be the topic of Session 14: Additive manufacturing of large components with a keynote speech from industry by Dr. Wolfgang Meyer, Head of Central Function and Innovations, Volkswagen AG and two scientific presentations by IKV. For further information cklick <a href="https://en.kunststoffe.de/a/news/research-meets-practice-2769135" target="_blank">here</a>.

issue 02/2023

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