Additive manufacturing:
Customised solutions for small series
small series and prototypes
Additive manufacturing, also known as 3D printing, is revolutionising the production of small series and prototypes. By building objects layer by layer directly from digital models, this technology enables unprecedented flexibility and speed in product development and the production of prototypes or small series.
We use the ARBURG freeformer 300-3X for this purpose. The patented ARBURG plastic freeforming (AKF) process enables the industrial additive production of technical functional components.
What makes the ARBURG freeformer special is the ability to process qualified standard granulates, similar to conventional plastic injection moulding.
The material is melted in a special plasticising screw and discharged as tiny plastic droplets in millisecond cycles via a high-frequency and high-precision piezo nozzle valve. The exact positioning is realised with the help of a moving 3-axis component carrier. In this way, a three-dimensional plastic part is built up layer by layer.
Our ARBURG freeformer 300-3X is equipped with 3 discharge units and an installation space of 234x134x230 mm. These features enable the production of multi-component parts or the manufacture of highly complex geometries or movable assemblies through the use of water-soluble support material.
The ARBURG freeformer is designed as an open system. By adjusting the slice and process parameters, properties such as component density, tensile strength etc. can be customised. Depending on the material, tensile strength can be achieved in a similar way to injection moulding.
The maximum mould cavity temperature of the ARBURG freeformer 300-3X is up to 200 degrees. In addition to the currently qualied materials (ABS, PP, PA, PC, TPE, TPU), this also enables the processing of various highstrength and flameretardant materials.
With the ARBURG freeformer, a component accuracy of +/- 0.1 mm and a minimum layer thickness of 0.2 mm can be produced.
Additive manufacturing
Advantages in overview
- Additive manufacturing from qualified standard granulates
- Flexible component optimisation and material qualification
- High part quality
- Technical functional parts - also multi-component
- Suitable for small series and prototypes
- Very high flexibility and speed in product development
Additive manufacturing
Solution for small series and prototype production
Solution in small series production
The production of small series presents companies with special challenges: While flexibility and adaptability to customer-specific requirements are paramount, costs and production times must be optimised at the same time.
Additive manufacturing offers efficient solutions for this:
Benefits in detail
Variety of materials:
The freeformer allows standard granulates to be processed flexibly without the need for prefabricated materials such as resins, powders or strands. This means you have a large selection of materials, original materials (TPEs with different Shore hardnesses, semi-crystalline PP, biopolymers, materials with flame protection or medical polylactide) and various colours at your disposal.
Open system:
Thanks to the open system concept, slice and process parameters are freely programmable and can therefore be customised at any time. Your modified materials can also be quickly made ready for use and utilised.
Multi-component technology:
The standard integration of several discharge units enables the production of components in different material and colour combinations - even as resilient hard-soft joints.
Solution in the production of prototypes
Prototypes play a decisive role in the development and elaboration of new products and ideas. They make it possible to test design concepts, check functions and optimise products before they are launched on the market and to have them in your hands beforehand.
Additive manufacturing also offers significant advantages here:
Benefits in detail
Fast
Iterations:
The speed of additive manufacturing makes it possible to create and test several prototype versions in a short space of time. This speeds up the development process, as design adjustments can be quickly implemented and retested.
Realistic
functional prototypes:
Advanced materials can be used to produce prototypes that come very close to the properties of the end product. This enables realistic functional tests and performance checks.
Complex
geometries and customisation:
Additive manufacturing shows its strengths particularly when it comes to products with complex structures or customisations. Prototypes can be produced without the limitations of conventional manufacturing processes, which enables the exact realisation of the design.
Areas of application
of additive manufacturing
Additive manufacturing, often referred to as 3D printing, plays a transformative role in various industries.
With the ability to manufacture directly from digital data, it enables unrivalled flexibility and speed in the production of small batches and prototypes. Here are the specific applications and their dependencies on this technology explained in detail:
Medical technology
In medical technology, additive manufacturing enables the production of customised solutions that are tailored to the individual needs of patients.
From customised prototypes to surgical tools and anatomical models for preoperative planning, additive manufacturing offers unrivalled customisation options. This technology not only supports improved patient care through personalised medical products, but also enables rapid prototyping of new medical devices.
The ability to realise complex geometries without the constraints of traditional manufacturing methods also promotes innovation in medical research and product development.
Aerospace industry
In the aerospace industry, the focus is on optimising performance and efficiency.
Additive manufacturing enables the production of lightweight components with complex, functionally optimised structures that traditional manufacturing methods cannot produce or can only produce at high cost. This technology is used to reduce fuel consumption and emissions by enabling the production of parts that are both lighter and more resilient. In addition, additive manufacturing allows the integration of functions such as cooling channels and structural reinforcements into a single component, which simplifies assembly and increases reliability.
The rapid production of prototypes significantly accelerates the development cycles of new aerospace components.
Automotive industry
The automotive industry is increasingly utilising additive manufacturing for the development of prototypes and the production of end parts in small batches.
This technology supports the realisation of innovative design concepts, the optimisation of components for performance and efficiency and the reduction of weight and material consumption. The ability to produce complex structures and cavity geometries without additional costs for tools or moulds opens up new possibilities in vehicle design.
In addition, rapid prototype development enables efficient review and optimisation of designs, resulting in faster time-to-market for new models.
Electronics
The electronics industry benefits from additive manufacturing thanks to the ability to produce complex housings and components with precise tolerances and specific properties.
This technology enables a high degree of design flexibility for the integration of heat sinks, connection ports and other functional elements into electronic components. The fast and cost-efficient production of prototypes promotes innovation and enables electronic products to be brought to market more quickly.
Additive manufacturing also supports the production of small batches of specialised electronic components that require adaptation to specific requirements or integration into customer-specific systems.
Special applications
Additive manufacturing is also used in a range of special applications, from the on-demand production of spare parts and the manufacture of tools and devices to customised design and art objects.
This technology makes it possible to manufacture parts and products quickly, flexibly and without the need for extensive stocks or expensive moulds.
In particular, the ability to produce discontinued or hard-to-find spare parts on demand is revolutionising maintenance and after-sales management in many industries.
Additive manufacturing
This can be additively manufactured
Car side mirror housing
Material:
ABS Terluran GP35 + PA10 Grilamid BTR 600
- Painted car side mirror
- Example of surface finishing of additively manufactured components
Ribbon cable
Material:
TPU WT 65 S 720/1
- Integrated conductor tracks
- Electrically conductive and flexible
Air injector
Material:
PC Lexan 940
- Flame-retardant special material
- Original material certified for aerospace applications
- High geometric accuracy
Electrical plug
Material:
PC-ABS Bayblend T65 XF
- Flame-retardant special material
- Production of filigree structures
- High geometric accuracy
Planetary gearbox
Material:
ARBOBLEND + TPU Elastollan C78A (80 Shore A)
- Biodegradable biopolymer
- Movable assembly without mounting
- High geometric accuracy
- Hard-soft connection
Toothbrush with soft touch
Material:
ABS Terluran GP 35 + TPU Desmopan 9385 A (80 Shore A)
- 3-component application incl. support material
- Complex resilient hard-soft connection
- Haptically optimised component - accelerated time-to-market
Feather
Material:
ABS Terluran GP35 + TPU Desmopan 9385 A
- Three-component part with flexible soft component and support material
- Durable hard-soft connection
- Flexible spring with customised eyelet
Connecting hose
Material:
TPU Desmopan 9370 AU black
- Real use in the engine compartment of a prototype vehicle
- Reversible, tear-resistant and leak-proof
The benefits of collaboration with HECHT + DIEPER
HECHT + DIEPER is your expert in injection moulding of plastics.
Expertise
During development, our customers benefit from our many years of expert knowledge, in the area of design, our own toolmaking, as well as our competence in production.
Partnership
Together - as specialists, we know that only the joint development of components is the best prerequisite for the optimal functionality of your product.
Experience
Since more than over 40 years we have been developing and producing technically challenging components of the highest precision for various industries.
Logistic
In order to be able to deliver quickly, we believe in long standing and reliable cooperation with local logistics partners.
Efficiency
Regular optimization in development, toolmaking and production is a continuous process for us and thus the foundation for high efficiency and customer satisfaction.
Local
Everything is local. We develop and produce plastic components - from the idea to production - one-stop. Our service enables short communication channels.