Additive manufacturing (AM) is the darling of small parts makers everywhere, especially for small batches, prototypes and customization.
As a production technology, AM provides definite advantages when dealing with a small quantity of small, complex parts, but many manufacturing engineers come up scratching their heads when they consider the drawbacks of this technology: the low lead time is seemingly countered by the long build time, and the capability of high complexity is countered by anisotropy and low durability. The confounding thing about AM is that it seems so full of potential—but that potential is largely out of reach of those who have a conventional manufacturing mindset.
In this video, igus, the German motion plastics company, showed us its approach to harnessing the potential of AM while mitigating its weaknesses. The company’s solution: using 3D-printed molds in common injection molding machines to manufacture injection molded gears.
The process was developed for igus’ main business: advanced polymers. The company makes many types of polymers with advanced properties, such as temperature resistance, self-lubrication, low coefficient of friction, and high degree of toughness. igus has a 3D printing division that is exploring the potential of AM technology. However, while the technology’s arsenal of materials is ever growing, it does not yet include the advanced plastics of igus.
The solution: capitalize on AM’s low lead time, and follow it up with injection molding—a technology that produces strong parts from a wide array of materials options.
The mold inserts, which are printed on a fused deposition modeling (FDM) machine, fit into a standard steel base. Despite the harsh environment, the printed tools can last for thousands of cycles, in the case of low-temperature plastics, and hundreds of cycles under harsher temperature conditions.
Check out the video above to see an example of a printed mold—and the gear made in it—which is made of a special igus iglide polymer material.
Igus provides this innovative production technique as a service to its customers, but the principle shows that additive manufacturing still has plenty of unrealized potential in the industrial manufacturing space.
For more innovative technology from igus, stay tuned for our upcoming videos.