ARBURG Plastic Freeforming
Lim Wei Yen / Manager for Additive Manufacturing
New Industrial Additive Process
Facts and Figures • Employees:
~ 2.400 worldwide ~ 2.000 Germany
• Consolidated turnover 2014: ~ 540 million euros
• Export share: ~ 60 %
• In-house production share: > 60 %
The family-owned business
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Centrally production in Lossburg / black forest
with around 146,000 m²
Motto: „ ARBURG for efficient injection moulding“ • High-tech
injection moulding technology - Clamping forces from
125 to 5,000 kN - Moulded part weights
from 0.001 to 2,583 g PS
• Robotic systems and Turnkey projects
• Technical consultation
The family-owned business
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ARBURG Plastic-Freeforming
Agenda • Introduction
• Technology: freeformer and plastic-freeforming
• Material and Properties
• Examples of application
• Summary and future targets
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Introduction
Market requirements are changing
Short product lifecycles
Rapid technical development
The desire for customised
products
Increasing variety of
product versions
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Principal process sequence
Introduction
6
“Software”: layer-by-layer
geometric breakdown
“Hardware”: layer-by-layer
geometric build-up
Finished component
Basis: 3D CAD data
(STL files)
New ideas from plastic
New product as one-off part
Specific data processing
Additive manufacturing
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Process principle in detail
Technology: Freeformer and plastic-freeforming
Actuator to open and close nozzle
Injection molding like material preparation with 3 zone screw
Diaphragm to open and close nozzle
Material basis: standard granulate
Discharge of single droplets
Pressurized material reservoir between screw and nozzle
x
y
z
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Technology: Freeformer and plastic-freeforming
Freeformer System – main components
Fixed discharge heads incl. pulsed open and close nozzles
Moveable platform is moving in X-Y and Z direction layer by layer
Data and facts - Discharge frequenzy:
70 up to max. 200 droplets - Typical melt pressure
is about 500 bars
Material prepartation with plastification screw
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Technology: Freeformer and plastic-freeforming
Influence factors • Surface quality:
droplet / nozzle size
• Density: Material, filling strategy and processing parameters
• Mechanical properties: processing parameters e.g. chamber temperature
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Homogeneous and dense layer
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Technology: Freeformer and plastic-freeforming
Selection of different nozzle sizes [100 µm] in progress
150 µm 200 µm 250 µm [300 µm] in progress
fast slow
tight Very tight
Production speed
rough smooth
Layer density
Surface
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Technology: Freeformer and plastic-freeforming
Integrated material preparation • In principle all unfilled
Standard/customer- specific granules
• Good material availability
• Specific dyed material
• More cost efficient use of material
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Actual material situation • ABS, TPU, PC and
amorphous PA12
• Actual development: PA 6 and PP
• Actual limitations - Chamber Temperature(max. 100°C)
- Melt temperature (max. 330 °C)
- Material temperature resistance
Material and Properties
12
Photo: Part for material qualification
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Material and Properties
Application example: tensile test samples
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Material and Properties
1 mm
Tensile tests for Terluran GP 35 (ABS)
Additive manufacturing
Moulded
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15
Tensile strenghts APF ABS Terluran GP 35
Comparison to Injection Molding
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0
20
40
60
80
100
[%]
upright flat side
SD 0,215 mm
SD 0,210 mm
SD 0,205 mm
[MPa] 40
20
30
10
Material and Properties
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Examples of Applications
Two-component processing • Variety of materials
and colours can be processed - in one step
- in one component
• Use of water soluble support material (PVP)
• Functional and durable hard/soft combinations
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Small scale production and function integration
Examples of Applications
17
60 fixations for LED lamps Material: ABS Layer thickness: 0,215 mm Production time : ca. 14 hours
Key chain Component material: ABS Layer thickness: 0.27 mm Production time: approx. 1 hour
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Examples of Applications
Multi-component parts
Plate with sealing Material: ABS + TPE (80 Shore) Layer thickness: 0,260 mm Production time: ca. 1 hour
Coloring with Masterbatch
Gripper with sealing lip Material: ABS + TPE (80 Shore) Layer thickness: 0,215 mm Production time: ca. 9,5 hours
Integrated media channels
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Complex geometries using support structure
Examples of Applications
Bellows Material: TPU (80 Shore) Layer thickness: 0,275 mm Production time: ca. 2,5 hours
Housing Material: ABS Layer thickness: 0,260 mm Production time: ca. 5 hours
special water soluble support material*
* BASF Material auf Basis von Polyvinylpyrolidon
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Examples of Applications
Use Freeforming to Individualise massproducts
Scissor Material: PP Layer thickness: 0,210 mm Production time: 1 min. for individualisation
Light switch Material: ABS + TPU Layer thickness: 0,215 mm Production time: 5 min. for individualisation
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Summary and Future Targets
APF – a future technology • Drop by drop
(high dense, structured surface)
• Open System : Adjustable machine parameters
• A lot of Materials possible
• 2 Component applications (e.g. ABS-ABS, ABS-TPU, ABS-Support)
• Mechanical Properties close to injection molded parts
• Qualification of PA6 and PP
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Summary and Future Targets
Extended process: Five-axis component carrier
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Two additional rotary axes
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Complex geometries without support structure
Summary and Future Targets
23
Impeller Material: ABS Layer thickness: 0,260 mm Production time: ca. 2,5 hours
Cross Material: ABS Layer thickness: 0,200 mm Production time: ca. 6 hours
© Copyright by ARBURG 2015-09 / MPMA Conference – 3D Printing / KL
ARBURG Plastic Freeforming
Lim Wei Yen/ Manager for Additive Manufacturing
New Industrial Additive Process