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technology | 3D printing Right: This


custom cranial implant was produced on Arburg’s


Freeformer


system using a medical grade PLA


temperature management of all components involved in the build chamber needs to be optimised.” One of the challenges faced by many users of


Right: Igus uses Arburg’s Freeformer to produce parts for functional gears


“Additive manufacturing processes are very interest- ing when it comes to weight reduction and lightweight construction. For example, bionically-optimised parts can be designed and produced without having to consider the technical production constraints that apply to injection moulding. However, in order to produce optimum parts in the additive manufacturing process, the design of the parts must be compatible with the technology and the manufacturing process. Within this context, many questions regarding design guidelines still need to be answered,” he says. “Another advantage is the opportunity afforded for functional integration. Additive production technology combines part production and assembly in a single process step, something that would normally involve two sequential steps.” According to Duffner, Arburg is


developing the Freeformer and its Arburg Plastic Freeforming (APF) technologies on an ongoing and practical basis. “The focus is on the qualification of materials and process stability. In the case of semi-crystalline materials, we have to deal above all with the shrinkage and the resulting distortion, while for the processing of high-temperature materials complete


additive manufacturing technology is the limited number of materials available to them – and the high material prices of the filament or powder-based resins. From conception, Arburg’s aim for the Freeformer was that it should use the same low-cost plastic granules that would be run in an injection moulding machine. It has qualified a growing range of polymers and, to date, has shown examples of a gear component manufac- tured in a flame retardant PC/ABS blend; a two-com- ponent planetary roller screw drive made from BASF’s flexible Elastollan TPU and a biodegradable Arboblend PHA from Tecnaro; a nutcracker made from EMS Grilamid bio-based polyamide; and an implant pro- duced in a resorbable Resomer medical grade polylac- tide from Evonik that dissolves inside the body after a defined period of time.


Igus drives ahead One company using Freeformer to make 3D printed parts from its own high performance plastics is Igus. The German manufacturer of drive chain systems and bearings lists a product line extending to 100,000 variants, most of which are available ex-stock. Each year, it extends its range with the develop- ment of between150 and 250 new products. Igus uses its Freeformer to produce functional parts and prototypes, mostly using its standard range of lubricant-free, abrasion-


resistant granular moulding materials (its Iglidur tribologially-modified plastics exhibit excellent glide performance without use


of external lubricants and are used for corrosion- and wear-resistant bearings). Igus operates around 350 injection moulding


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