3D Printing Applications

Applications of the 3D printing used at IPF.

Overmoulding

Overmolding is a molding process in which two or more materials are combined to produce a single part. Typically the part seamlessly binds a rigid plastic with a rubber-like elastomer. The result is a soft-touch, non-slip surface common on power tools, toothbrushes, razors, consumer electronics, medical devices and more.

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Shock Absorbtion

Shock/energy-absorbing components are often used as a safety measure to absorb runaway energy in case of a component or system failure. Practical examples of shock absorbing components include bumpers, isolators, fasteners, mounts, spacers and pads.

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Gaskets, Plugs and Seals

Gaskets:
A gasket (See figure below) is a mechanical seal that fills the space between two mating surfaces. Also called a seal, a gasket is generally used to prevent leakage from or into joined objects while under compression.

Plugs:
A plug is a piece of material used to stop up a hole or aperture, to fill a gap, or to act as a wedge. For example, plugs for sanitation are used to firmly close a drainage outlet in bathtubs, washbasins or sinks (see figure below). To ensure a tight seal, plugs are typically made from a soft material such as rubber or have a soft outer ring so that they can be fitted to holes slightly smaller than their diameter.

Valves:
A valve is a device that regulates the flow of a fluid (gases, liquids, fluidized solids or slurries) by opening, closing or partially obstructing a passageway. Valves are used in a variety of contexts, including industrial, military, commercial, residential and transportation. Plumbing valves, such as taps for hot and cold tap water, are the most noticeable types of valves. Other valves encountered on a daily basis include gas control valves on cookers, small valves fitted to washing machines and dishwashers, and safety devices fitted to hot water systems.

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Living Hinges

A living hinge is a thin flexible hinge (flexure bearing) made from plastic, as opposed to cloth, leather, or some other substance, that joins two rigid plastic parts. The hinge allows the plastic parts to bend along the line of the hinge. It is typically manufactured in an injection molding process that creates all three parts at one time as a single entity. A thinned section of the plastic part bends to allow movement. The hinge's minimal friction and little wear make it useful in the design of micro electromechanical systems. If correctly designed and constructed, living hinges remain functional throughout a product's lifetime as these hinges can flex more than a million cycles without failure. Polyethylene and polypropylene are considered to be the best resins for living hinges due to their excellent fatigue resistance. The low cost and ease of manufacturing makes them quite common in disposable packaging. 

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Multi Material Printing

Overview
In recent years, thermoplastic elastomers (TPE) based multi-material molded products have found widespread use in various industries and in daily life. The soft touch surface provides a non-slip grip and ergonomic comfort. Many industries use soft touch coating during their product design to validate future products. For example, the automotive industry uses soft touch in the design and development of interior products such as knobs, pulls and handles. Consumer electronics use soft touch coating for features such as rubberized buttons and coatings, typically to improve the product's ergonomic comfort. In the world of consumer goods, a vast array of products incorporate soft touch coating, including tooth brushes, shaving handles and glasses.

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Impact Resistance

Impact resistance, or toughness, is defined by the relative susceptibility of plastics to fracture under stresses applied at high speeds. In materials science and metallurgy, impact resistance is a material's resistance to fracture when stressed. It is defined as the amount of energy per volume that a material can absorb before rupturing.

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Dynamic Friction Coefficient

Friction is defined as the force that opposes the relative motion or tendency of such motion of two surfaces in contact. The friction coefficient of a prototype’s surface is a functional component, not an aesthetic one, and simulates the end product’s mechanical properties. A well-designed prototype that takes friction into consideration can have the following advantages: an improved grip for the enduser, reduced part wear, simulated movement functionality and sliding abilities.

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Labeling and Texturing

Texturing:

Texturing is primarily used for visualization, appearance and rendering purposes. Among its other benefits, texturing allows for product differentiation and customization – a highly valued trait in today’s market environment. 3D texture applications are used to decorate parts, exhibit a unique appearance or demonstrate a higher value. 3D texture data technologies enable designers to design a texture before manufacturing.

Labeling:
Labeling allows for product recognition to be part of the product design, as well as for a closer resemblance to the end product. Although most commonly applied to consumer goods and consumer electronics, labeling remains extremely popular in most industries because It lets manufacturers strengthen brand identity, as well as providing the user guidance on how to utilize the product. Techniques for labeling vary from painting techniques to backlit display techniques. 

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RAPID PROTOTYPING

Connex500 Twin Shot Wheel Prototype. Wheel is printed in a rigid Vero White and the tyre printed in Tango Black 61 shore A. All printed simultaneously with no need for any assembly.

3D Printing - Multi Material - Rigid & Flexible Prototyping

3D Capabilities

Connex 500 - Flexible & Rigid Materials

  • 30 digital materials including variable shore hardness materials from 27 A shore up to 95 A shore, enabling flexible and rigid materials in the same prototype
  • High resolution mode, 600 DPI in X & Y – enables models with fine features
  • Smooth surface finish -- Eliminates the stair effect
  • Thin walls down to 0.6mm (0.024”)
  • Layer thickness ultra thin 16microns or high speed 30microns
  • Fine detail in all axis
  • Large build size 500 x 400 x 200mm


Perfactory - Ultra Fine Prototyping

  • Perfect for use for when needing incredible detail
  • Very High Quality of Parts
  • Excellent surface finish
  • Superb detail and accuracy
  • Build resolution from 16(X) x 16(Y) x 15(Z) microns to 30(X) x 30(Y) x 100(Z) microns

Resins for;

  • Investment casting,
  • Bio-compatible grade 2 applications,
  • High temperature applications
  • General high quality prototypes


Object Eden 350V

  • Layer thickness ultra thin 16microns and high speed 30microns.
  • Selection of colours available including Transparent, Black, White, Blue and Grey 
  • Minimal stair effect, i.e. smooth side walls.
  • Large build size 350 x 350 x 200mm (Material can be cemented together to produce larger models)
  • Complicated geometries, i.e. overhangs and undercuts achievable.
  • Durable material enables snap fit and functional applications.
  • Material can be machined, drilled, tapped, polished, painted and chrome-plated.
  • Ideal for producing masters for silicon moulds to produce vacuum castings

Tweets from Gary

Tweets from Gary

Popup Module

This is the Popup Module feature. Assign any module to the popup module position, and ensure that the Popup Feature is enabled in the Gantry Administrator.

You can configure its height and width from the Gantry Administrator.

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