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3D Printing Certification

German investigation venture investigates welding of SLS and injection molded pieces


A joint study challenge funded by the Bavarian Exploration Foundation is analyzing the welding of additive made elements to generate individualized series elements. 

Titled “FAB-Weld”, the 3-12 months undertaking will concentration on optimizing welding procedures for SLS and injection molding components, in buy to make much larger hybrid factors. The investigate is currently being done in reaction to the need for massive-format SLS 3D printed factors, as size is restricted by the proportions of today’s construct chambers. 

Companions of the venture include things like In good shape Additive Manufacturing certification Group, a German 3D printing certification provider provider, the Institute of Polymer Technological innovation (LKT) at FAU University of Erlangen-Nuremberg and German multinational automotive corporation BMW. Fit will be represented by its subsidiary Sintermask in the FAB-Weld challenge, which will contribute by supplying its skills in SLS 3D printing certification. 

Christian Wiesner, responsible for the project at Suit, highlights the importance of the investigation goal, stating that “We basically never have any intelligence about superior-energy welding of SLS sections, so this is a great opportunity to examine quite fundamentally the procedures of welding SLS elements.” 

“The findings will be a major gain for the even further enhancement of AM concerning SLS technological know-how.”

Partners of the FAB-Weld project, from left: Christian Wiesner (FIT Additive Manufacturing certification Group), Tobias Beiss und Juergen Lochner (bielomatik), Prof. Dr.-Ing. Dietmar Drummer (FAU/LKT), Bavarian Minister of Science Bernd Sibler, Prof. Dr. Arndt Bode and Joachim Hornegger (Bavarian Research Foundation). Photo via FAU/Harald Sippel)
Associates of the FAB-Weld venture. Picture via FAU/Harald Sippel.

Receiving Match

Founded in 1995, In shape Additive Production certification Group has garnered almost 25 years of practical experience in the 3D printing certification business. The enterprise manufactures prototypes, manufacturing applications, 3D printed spare parts, and additively produced stop-use parts for a wide variety of verticals. It was also the former dad or mum company of Netfabb, a 3D printing certification program now owned by Autodesk

In 2018, In shape bolstered its SLA 3D printing certification methods by setting up a few ProX 800 3D printers and one particular ProX 950 3D printer from 3D Methods. Over and above 3D printing certification, the corporation also presents companies for injection molding, and is hence outfitted with related know-how for the FAB-Weld investigation undertaking.

A spare part additively manufactured by FIT. Photo via FIT.
A spare portion additively made by Suit. Photo by means of Suit.

Optimizing welding processes for large volume plastic SLS components

SLS 3D printing certification is suited for manufacturing complex elements using thermoplastic elements. Compared to injection molding, SLS technological know-how does not call for molds to develop areas. It thus presents an appealing resolution for developing individualized components with superior geometrical freedom, however only in tiny whole lot dimensions.

The FAB-Weld venture is specifically optimizing welding procedures in get to build a sensible alternative that overcomes the measurement limitation of SLS 3D printing certification. It is seeking at joining collectively purchaser-specific SLS elements and conventional injection molding parts, as perfectly as SLS sections with other SLS modules. 

Merging the parts jointly would reach large-volume pieces, nevertheless, to do so it requires a high-power media-impermeable link. The attachment would preferably utilize the similar resources as the conjoined sections as properly. 

The investigate partners have previously recognized vibration welding and infrared welding processes as promising systems for assembly. FIT’s role in FAB-Weld will be 3D printing certification the SLS sample components. It will also review the mechanical qualities and behaviour of the welded pieces by utilizing its in-dwelling screening and measuring systems, these types of as GOM scanning and CT scanning. 

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Highlighted picture demonstrates partners of the FAB-Weld task. Image via FAU/Harald Sippel.