ADDITIVE MANUFACTURING/3D PRINTING
FEATURE SPEEDING UP CONNECTOR INNOVATION WITH 3D PRINTING
LAPP explains how additive manufacturing (AM) is reshaping the way it delivers custom products for its customers
through a series of quality tests. If the design fails a test, it is quick and easy to adjust the design. Once amended, it is ready for reprint and further testing, all without using precious resources and materials. This is one way LAPP has
as possible, and for as little as possible. But, developing, testing, and manufacturing bespoke products is inherently slow. At least, until now. Additive manufacturing (AM), more
M
commonly known as 3D printing, has been touted as the next big thing for 40 years. In reality, this technology has remained relatively niche without large-scale adoption. But now, LAPP, a leading provider of intelligent
connection solutions, is embedding AM into many of its processes. This makes it easier to design custom solutions, cheaper to prototype, and faster to produce. Utilising AM, LAPP is passing the efficiency savings onto their customers in industries ranging food and beverage to renewable power and data centres.
EXPANDING THE APPLICATIONS 3D printing dates back to 1983, when US engineer Chuck Hull developed the stereolithography (SLA) process. This used liquid resin, which cures layer by layer using a UV laser to create an object. He patented the technology in 1986. Others later developed different processes such as fused deposition modelling (FDM) and selective laser sintering (SLS). All these methods had one thing in common: their foundation is the principle of adding material rather than removing it. While remaining as an experimental
technology, AM has developed significantly in recent years. As the equipment and delivery of the technology have steadily improved, the materials used in it have expanded. This makes the process cheaper and more accurate. Today, many industries are embracing these
technologies to speed up their processes and reduce costs of trial and error in development. For the past few years, product development has been the primary use for AM because it is a quick and cost-effective way to make one item to be put
anufacturers offering custom solutions face a dilemma. They’re under pressure to produce as much as possible, as fast
integrated the technology into its processes. Dr. Phillip Baron, research engineer Advanced Technology at LAPP, explains: “We use 3D printing to continuously produce prototypes that we use internally to realise ideas and design drafts within a very short time. This allows us to test many parts efficiently and use them for research or, for example, to check their pluggability.” Once the 3D-printed version stands up to the
task, the design can go ahead with manufacturing in the product materials. However, AM technology has shifted into series production thanks to an increase in material diversity and more powerful printers. Manufacturing companies can now use it to make complex components that are too intricate to make through traditional methods. This has been especially impactful for LAPP, which is expanding its use of 3D printing to series production. The team that makes LAPP’s EPIC connectors are currently assessing the use of 3D printing in series production. Meanwhile, LAPP’s Harnessing Solutions Hub in Singapore is also actively using this technique to develop and produce custom solutions. While it is yet to be fully integrated into the making of cables, it is an innovation that has been embraced in the making of connectors. LAPP has invested in this, and the Stuttgart site is a state-of-the-art facility for prototyping and series production using AM. They have also created the Additive Manufacturing Tech Council, led by Stefan Kurz and Dr. Susanne Krichel. This brings together everyone at LAPP using AM to share their knowledge and coordinate their efforts.
FAST SOLUTIONS FOR LESS Processes are more flexible and efficient with 3D printing within connector production. The ability to produce a prototype quickly enables the teams at LAPP to realise ideas and test designs in less time, and adjust their designs within a matter of hours or days, helping create the ideal solution without unnecessary delays. This is because the use of AM makes the process very flexible and efficient. They can also consider customer-specific needs, easily seeing how the design can meet
needs in various ways. This increases product quality and customer satisfaction. Because the final product solves unique challenges faced by the customer. Of course, a shorter
development time also leads to a shorter delivery time. This
allows LAPP to get bespoke solutions
to its clients fast without compromising quality. All these benefits lead to cost savings
throughout the development phase. The prototyping phase itself is cheaper with 3D printing because it is all digital. Changes in CAD designs are easy to make for new iterations without the need for hours of human labour to redesign basic mock-ups. Additionally, material costs are lower because consumption of raw materials is lower; and less waste is produced as AM uses the exact amount of material needed.
SEEING THE EFFICIENCY IN ACTION A customer recently approached LAPP with a challenge. Despite installing built-in dehumidifiers, condensation was forming in their cabinets. This ran towards the connectors inserted through the floor, risking malfunctions and short circuits. They had tried laser-cut stainless-steel components to shield the connector from the liquid, but this was costly, complex, and didn’t offer 100% protection. For LAPP, the goal was simple: to provide a solution that kept moisture out while being compatible with standard components. With the help of 3D printing, the company
was able to develop and test a concept. Baron comments: “Just three days later, the first prototypes ready for series production were completed in LAPP Orange – technically feasible for series production with a UL- certified material.” This shows the efficiency and flexibility
offered by AM, as well as how it makes solving customer’s unique challenges easier. As the technology continues to evolve and expand its capabilities, LAPP will continue to embrace it. “In principle, 3D printing allows decentralised, demand-driven production directly on site – without long delivery times or tooling costs, which can be a real competitive advantage, especially in times of geopolitical uncertainty and volatile markets,” concludes Baron.
LAPP
www.lapp.com/en_GB/gb/GBP/
https://lappconnect.lappgroup.com/en/expertise /additive-manufacturing/
NOVEMBER 2025 DESIGN SOLUTIONS 35
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