While the additive manufacturing processes, e.g. powder, liquid polymer or filament-based, have so far mainly been used for rapid prototyping methods, these processes together with the suitable materials have been continuously further developed, so that one can now speak of a direct manufacturing approach.

Especially in the selective laser sintering process (SLS, or LS according to DIN EN ISO / ASTM 52900), it is possible to manufacture components without support structures, very filigree and with high mechanical properties at the same time. Historically, the SLS process developed together with the thermoplastic material polyamide 12 (PA12) and is now very well researched and is offered as a stable process.

With this technical plastic it is possible to use components with high mechanical properties, comparable to injection molded components. The high ductility of the material also enables the design, for example, of film hinges, elastic structures or even flexible elements. Nevertheless, this material also sometimes reaches its limits, so that there is currently a lot of research and development on new SLS materials.

A very interesting material for selective laser sintering is the very flexible and soft thermoplastic polyurethane (TPU). This enables properties similar to rubber and can be used, for example, for seals, sealing profiles, anti-slip coverings, handles, bellows or flexible grippers. Especially in combination with the structurally stable plastic PA12, these two materials enable the implementation of the most complex prototypes as well as finished assemblies.

 

The ability to combine 3D printed rubber-like parts with 3D printed solid structures enables the realization of completely new prototypes, assemblies and functional parts directly for the application.

 

While the topic of individualization and small series production is becoming increasingly important, these requirements are not in relation to the high investment costs for correspondingly complex injection molds. For this reason, it usually makes more sense to manufacture these components directly in 3D printing for small quantities (direct manufacturing). Depending on the size and complexity of the component, series components of up to 6,000 pieces are usually cheaper in industrial 3D printing than investing in costly injection molds.

 

In particular, with a sensible design of the components, any assembly steps and the production of several individual components for an assembly can be reduced to a single assembly, which in the best case can be directly functionally additively manufactured and also saves weight.

Talk to us if you are interested in 3D printed components, in a CAD design suitable for your application, in SLS PA12 or TPU powder. We're here to help.

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