PRODUCT DEVELOPMENT | TECHNOLOGY
qualifying their own materials with great success and using them to produce functional parts. “For example, Igus is using the Freeformer to manufacture the company’s own lubricant-free, abrasion- resistant materials for corrosion and wear-resistant plain bearings in an additive process,” says Duffner. “At the central Arburg production location in Lossburg, Germany, we use the Freeformer for the additive manufacturing of its own parts; for example, the housing for its main switch and transport stabilisers used for shipping.” According to Arburg, its technology consultants verify precisely whether the Freeformer is in fact suitable for the required part and material in advance for potential customers. In order to produce prototypes quickly for this purpose, the Arburg Prototyping Centre was established at the Loss- burg headquarters this year, with six Freeformers at its disposal. Stratasys has developed PolyJet 3D printing for customisable, intricate, realistic prototypes and models. The company says that these can shorten design cycles and eliminates the need for costly tooling. The PolyJet-based J750 and Connex3 Colour, multi-material 3D printers can produce multi-material, coloured parts in a single print. The 3D printing process in Stratasys machines is fused deposition modelling (FDM). Stratasys says its multi-material printers enable designers to create the characteristics of a part without assembly or painting, allowing for more iterations early in the design process and unlocking creative freedom. The company has also developed Digital ABS, a
rigid, tough and opaque material to extend the simulation of engineering thermoplastics beyond the thermal resistance, toughness and transpar- ency of existing materials High Temperature Rigur and VeroClear. The material closely approximates ABS and compared with the averages for ABS1, Digital ABS has the same or higher values for strength, flexibility, durability and heat resistance. Its impact resistance is below average for ABS1 but still within the range of all ABS offerings, and three times that of its Vero material. Four digital materials simulate ABS - Digital ABS and Digital ABS2, both in green and ivory. The primary difference between them is that Digital ABS2 retains its rigidity and toughness in thin-walled parts of less than 1.2mm. Stratasys says that this makes Digital ABS2 ideal for
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consumer electronics and other consum- er goods, including small appliances and cell phones, which require high stability with thin-walled geometries. All of the Digital ABS
materials can be used for func- tional prototypes - even those with snap fits - patterns, prototype tooling for injection moulding and manufactur- ing aids such as jigs, fixtures and gauges. “PolyJet is a well-suited technology for printing injection moulds for production material prototypes and low volume manufactured parts because it offers the dimensional accuracy and surface finish the industry is used to,” says
Gil Robinson, Injection Moulding Use-Case Manager at Stratasys. “It also has one of the best throughputs in the industry, which
ensures production parts are created as quickly as possible. Furthermore, our PolyJet based Connex systems, enable our customers to print materials that are both temperature resistant and strong. In some cases, these properties make it possible to inject thousands of parts with one mould set.” Stratasys believes that PolyJet has a big poten- tial in the injection moulding sector. “The injection moulding industry is a $4bn industry and growing,” Robinson adds. “Also, the way the world is moving, contract manufacturers, OEMs, and design firms are constantly being pressured into delivering products faster with fewer resources. This has generated a need for tools that will facilitate this imperative and a 3D printer is one of those tools. The more people learn about the technology, the more they will understand its benefits compared to
Left: This injection mould, produced with Stratasys Digital ABS, is used to make overmoulded junction box prototypes
Below: Prototype component in injection mould, produced with Stratasys Digital ABS
October 2017 | INJECTION WORLD 63
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