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Precise 3D Printing Of Prototypes, Samples And Small Series

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Precise 3D Printing Of Prototypes, Samples And Small Series
Precise 3D Printing Of Prototypes, Samples And Small Series

Video: Precise 3D Printing Of Prototypes, Samples And Small Series

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Video: A look inside SLA technology: Precise 3D printing with advanced engineering materials 2023, January

Systec product designer Jochen Keuschnig knows from his own experience how difficult it is to find a manufacturer that can print larger components with high precision: “When we needed a true-to-scale prototype of a large-scale housing model, we approached various manufacturers. Most, however, have waved over because warp-free printing of large areas with high dimensional accuracy is extremely demanding. We therefore decided to use our expertise in positioning and control technology as well as software programming to develop our own 3D printer.”

In order to print large areas true to shape, even with inexpensive materials, the Systec developers had the idea of ​​designing a printer with a heated print cabin. The temperature in the work area can be kept stable just below the material glass transition temperature during printing, so that the shape cannot warp during printing. Supported by Bahr Modultechnik, the company built a fully operational prototype in just two months, which was first seen at the Bahr booth at the Hanover Fair in 2016. "There the device attracted keen interest due to its large installation space and the dimensional accuracy of up to 0.1 mm," recalls Keuschnig.

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As a proven specialist in modular positioning technology, Bahr contributed his know-how to the construction of the new printer. “We have been working closely with Bahr for a long time because we are using its linear axes in our drive sets. The modular design of the axle profiles with its extensive equipment and machining options is ideal for a flexible system structure and simplifies the implementation of customer-specific solutions and new developments,”explains Keuschnig. For the new 3D printer, Bahr has developed the closed, heated cabin with an integrated two-axis system and a base plate with a 720 mm working stroke. The print head is moved by H-kinematics, the linear axes of which have a robust and temperature-resistant toothed belt made of carbon. The axes achieve a positioning accuracy of 0,1 mm at a travel speed of 0.5 m / s. To lower the base plate, axes with a spindle drive were installed, whose travel speed is 0.04 m / s.

Prints using the melt layer process

Systec has developed the 3D printer further into series production under the name Inv3nt. The device, which is suitable for industrial use, produces low-warpage workpieces with high dimensional accuracy even with dimensions of 600 mm in length, width and height.

With fused filament fabrication (FFF) or fused deposition modeling (FDM), which is mostly called fused filament fabrication (FDM), thermoplastic filaments are heated in the print head and applied line by line to the working level from a nozzle. This method uses little material because only as much is used in the production process as is necessary for the print object and any necessary support structures. With commercially available filaments made of PLA and ABS, inexpensive thermoplastic printing media are available that are easy to process at low melting points, harden quickly and are also very storable and biocompatible. Depending on the printing task, the Systec printer can also be operated with filaments made of nylon, PET or thermoplastic elastomers.In order to produce workpieces with special material properties, filaments made of thermoplastic coated wood fibers or metal particles are also available, which give the objects a noble appearance, high strength and antistatic or magnetic properties.

In the pressurized air-heated cabin, the temperature is constantly adjusted to the glass transition temperature of the material in order to keep the product stable during the entire printing process. Because each thermoplastic has a different coefficient of expansion, the temperature must be precisely adjustable and controllable, since even small differences can lead to shape deviations in the millimeter range.

Content of the article:

  • Page 1: Precise 3D printing of prototypes, samples and small series
  • Page 2: Proven printing technology creates advantages

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