We use cookies to personalise content and ads, to provide social media features and to analyse our traffic. We also share information about your use of our site with our social media, advertising and analytics partners.Privacy Policy
Small Batches Are More Efficient

Small Batches Are More Efficient

Recently, Fraunhofer IPA researchers have developed a new technology that combines 3D printing with casting. In AFFC, the shell of the first part is printed and manufactured by FLM process, and then it is filled with a two-component resin. This saves time, increases the stability of components and allows printing of new materials.

In the free addition casting process, part of the shell is printed by FDM and then filled with a mixture of two components. ©Fraunhoff

Additional material manufacturing, also known as 3D printing, has brought a wide range of advantages to industry. IPA expert Jonas Fischer explained, "You enter the CAD data of a workpiece and you get a printed part." Small batches, models and individual parts are manufactured faster and more efficiently than injection moulding. In addition, you can create some complex structures and integrate some functions together. Of course, there are also some shortcomings.

Curing takes only three minutes

FLM (Fused Deposition) process is the most widely used 3D printing process at present. This creates cracks and voids. Jonas Fisher added: "This material does not appear entirely in the form of a model. This means that the mechanical properties of the components are worse. In addition, nozzles are used in each layer in FLM process. It takes a long time to build a large component. The third disadvantage is that only plastics that become soft when heated (called thermoplastics) can be used for FDM printing. Thermosetting plastics cannot be printed.

Fraunhofer's researchers have now found a way to minimize these shortcomings. They combined the printing process with the forming process for this. The first step is to fabricate part shell through FLM process. Experts use polyvinyl alcohol (PVA), a water-soluble synthetic polymer, as a printing material. Subsequently, the shell is automatically filled with precise quantities of polyurethane or epoxy resin. With polyurethane, it only takes three minutes to complete. Next, you can increase the number of components if necessary. Once the process is completed and partially hardened, it is placed in a water bath. The performance of the 3D printing workpiece created in this way is similar to that of the casting.

Small parts manufacturing is possible

In order to inject filling material into the mould, IPA researchers installed a special two-component material batching unit in a 3D printer. This means that it is possible to complete the whole process - printing the shell and filling. Printing process does not need to be interrupted, and it can be completely digital controlled like traditional 3D printing.

IPA researchers have confirmed the feasibility of this process and created several prototypes.

In addition, the program allows the use of two-component resins. Heat-resistant sleeves can be used as building materials. And components can be manufactured faster. Jonas Fisher added: "You just need to print the shell - gravity can do the rest of the work." Finally, when the material is fully filled, the stability of these components will be greatly improved, so there will be no pore or pore.

This new method is suitable for various application fields and industries. Fischer explained: "For example, it can be used for electrical isolation components, such as sockets. For example, the foam and cushion needed for safety is also applicable to this process. In principle, when only a few batches of large and complex components are needed, the free addition casting process is preferred. In addition, it is also conducive to weight loss.

Related News
  • The State Council

    The State Council

    May 28, 2019After Premier Li Keqiang signed the State Council issued in August 8th "," 13th Five-Year "National Science and technology innovation plan" (hereinafter referred to as the "plan"), clearly put forward...view
  • 3D Print Head Technology In Lucheng

    3D Print Head Technology In Lucheng

    May 28, 2019Sanya in May 18, in recent years, with the medical demand, accurate, personalized, 3D printing technology gradually in the domestic medicine clinical application in the open. Today, Third People's Hos...view
  • The Next 3~5 Years Will Enter The Era Of 3D Printing

    The Next 3~5 Years Will Enter The Era Of 3D Printing

    May 28, 2019The movie "cloud", the clone with a 3D printer in less than 2 seconds of time for the guests quickly making delicacy picture impressed the audience.Now this advanced printing technology has entered pe...view
  • 3D Printing To The Integration Of Traditional Manufacturing Industry

    3D Printing To The Integration Of Traditional Manufacturing Industry

    May 28, 2019The lack of core technology, Chinese manufacturing industry engaged in the lowest part of the profit processing industry chain manufacturing, which is Chinese manufacturing has been criticized as "the...view
  • Development Trend of CNC Machine Tools

    Development Trend of CNC Machine Tools

    August 1, 20191. High SpeedWith the rapid development of automobile, national defense, aviation and aerospace industries and the application of new materials such as aluminium alloy, the requirement of high-speed C...view
  • Bid Farewell To The Cold! 3D Printing Soft Octopus Robot

    Bid Farewell To The Cold! 3D Printing Soft Octopus Robot

    May 28, 20193D printing technology, which belongs to a kind of rapid prototyping technology, it is a digital model of a file, the use of powdered metal or plastic material can be bonded to construct an object lay...view

Contact Us