3D PRINTING | MATERIALS
Going large Germany-based Qbig says that 3D printing of oversized plastic parts offers advantages for tool-free production of small and medium-sized production runs. The company, whose 3D printing machines use its variable fused granulate fabrication (VFGF) process, recently held a technology forum at its Backnang facility. Eliminating the need for an injection moulding tool – and using granules, rather than filament, to 3D-print parts – helps to cut the cost of production, says the company. One example is a 3D cockpit of a helicopter
simulator at Murtfeldt Additive Solution, made using a Queen 1 system from Qbig. The dimen- sions of the cockpit are 2,260 x 1,780 x 1,705mm and it weighs 200kg. “We see enormous potential for product devel- opment with large-format 3D printing,” said Thomas Brinkmann, managing director at Impetus Plastics Engineering. “This also applies to lightweight construction, bionics and resource conservation.” Qbig says that its granule-based VFGF system
offers manufacturing advantages over other 3D printing techniques. For one, it says that filament costs seven times more than granulate. Johannes Lutz, CEO of 3D Industrie, said at the forum: “Demand for large-volume, additively manufactured components is increasing steadily. A VFGF printer offers significant cost advantages for the customer when it comes to the production of large components, as well as better profitability and amortisation for the 3D processor.” A key element of VFGF is the use of a variable
nozzle, which can vary between a turbo and a detailed build mode during the creation of a component. The variable nozzle can print quickly with high material throughputs (in turbo mode), used for in-fill areas inside the geometric form. In other areas of the component, high precision is
ensured with low material throughputs (in detail build mode). The variable nozzle of a Queen1 system works with a combination of 1.5mm (detail mode) and 3mm (turbo mode) and applies the material layer by layer. This makes it possible to produce very large-volume components without the use of moulds. The maximum processing speed is 500 mm/s. The system enables a dynamic output of 0.15-2.0 kg/h. In one example, it was used to make a pipe elbow for a hydroelectric power plant. It must be accurately fitted to pipes for a leak-proof connection, and withstand high pressure loads during use. Here, PLA was chosen as the material. The thickness of the component varies between 0.4mm and 1.2mm. Due to its large volume, and 205kg weight, printing time was 340 hours. Compared to a conventional process, the part was available in four weeks (instead of 16 weeks), and cost only half the amount to make.
Saving soles Ecofap is a project that aims to make shoe soles and heels with a new 3D printing material based on tanned leather waste. It will help solve the problem
Above: Qbig’s Queen 1 system was used to
3D-print the cockpit of a helicopter simulator
THERMOPLASTIC COMPOSITES
High-performing reinforced materials for Injecton Moulding and Additve Manufacturing
PERFORMANCE LIGHTWEIGHT
IMAGE: QBIG
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