First, the additive manufacturing speed is increased by 20 times and the service life is further improved.

In order to combine the advantages of additive and consumable manufacturing methods, Aachen Plastics Processing Research Institute (IKV) developed and successfully implemented a hybrid manufacturing unit.

The core component of the hybrid manufacturing unit is a modern 6-axis robotic positioning system with a standardized tool change system to ensure maximum automation and flexibility. In the method developed by IKV, the additive manufacturing step uses a screw-type plasticizing unit operated with plastic pellets. Compared to filament-based manufacturing techniques, this approach allows for high throughput while processing enhanced grade plastic compounds. In addition to increasing throughput, the cost is greatly reduced due to the use of more economical particles.

Precision filaments are very expensive to manufacture and are typically 10-30 times more expensive than the above methods of using plastic pellets.

In a hybrid manufacturing unit, the gripping system or milling tool can be connected to the positioning system as needed. Therefore, the unit can be subjected to other processing, such as providing a shape of the depositor to integrate additional functions or post-material processing to maintain dimensional accuracy.

Second, the definition

The process of layering components based on a 3D volume model is defined as additive or build manufacturing methods. These methods are often referred to as 3D printing. Conversely, reduced material manufacturing refers to the manufacture of parts by reducing material. For example, material blanks are used to create smaller parts by grinding, drilling or milling.

The 90 cm high rotor (left) manufactured by the IKV Hybrid Manufacturing Unit in 73 minutes and the surface properties of the manufactured parts recorded by the microscope (right).

Third, the new possibilities in the field of additive manufacturing

The processing of highly filled reinforced plastic compounds opens up new possibilities for additive manufacturing and is the core competence of AKRO-PLASTIC Encore, located in Lower Qisen, Germany. The carbon fiber reinforced AKROMID® B3 ICF 30 9 AM has been successfully applied to this newly developed fused deposition process (MDM process) by the Aachen Plastics Processing Institute (IKV).

Due to the better thermal conductivity of the carbon fiber reinforced compound, it results in a faster cooling rate, and the stability between the batch and the batch of the high-fill reinforced plastic, thereby achieving a stable manufacturing process with high production speed and obtaining Excellent mechanical properties. To improve ingredient and feed speeds, AKROMID® offers particles less than 1 mm in diameter for a finer dosing system that significantly reduces residence time.

Carbon fiber reinforced plastic particles

Nicolai Lammert - Aachen Plastics Processing Institute

Ultimate stress level

Nicolai Lammert is the head of the “Additive Manufacturing” team at the Aachen Plastics Processing Institute. He is responsible for the development and implementation of the hybrid manufacturing unit. He is very optimistic about the new method: “With our manufacturing technology and 30% carbon fiber reinforced polyamide 6, we are able to The ultimate stress level of the component is 148 MPa in the horizontal manufacturing direction (XY direction) and 40 MPa in the vertical manufacturing direction (Z direction).

The Z-direction performance is equivalent to 85% of the mechanical properties of pure nylon single-six base thermoplastics. Due to the flexible mobility of industrial robots, the anisotropy of compound materials and the high mechanical properties in the horizontal manufacturing direction can now be specifically tailored to the load path adjustment of mechanical properties in subsequent components. At the current 6 g/min discharge capacity, it can also increase the production speed to 20 g/min compared to the FLM-based manufacturing method. We also see more potential from here. ”

Contact:

Mr. Nicolai Lammert

Master of Science, Aachen University of Technology - Mold Technology / Additive Manufacturing Research Assistant

Mr. Jakob Onken

Master of Science, Aachen University of Technology - Assistant Professor of Component Design and Materials Technology

Dr. Jan Dormanns - SMP Deutschland GmbH

2. Large size parts

The use of a range of process-tested process thermoplastics can significantly increase production speeds, and hybrid manufacturing units are not limited to prototype production, but open up new possibilities for rapid manufacturing.

A typical application for such large-sized components is a conceptual study of highly integrated bionic support structures for the dashboard of the automotive supplier SMP Deutschland GmbH in Berchingen. Dr. Jan Dormanns, project manager of the pre-development, said: "In this bionic structure, the beams and intake pipes as well as the airbags, steering column, display and cladding components are combined into a single support unit.

With the overall concept of reducing the use of tools and saving over €1.5 million, rapid manufacturing can save costs for small-volume manufacturing of these structures. IKV's MDM method and AKRO-PLASTIC GmbH's compounds make a significant contribution to the future industrial viability of these concepts. ”

Future rapid manufacturing may be applied to: Conceptual study of the SMP Germany GmbH dashboard bionic support structure.

Contact:

Dr. Jan Dormanns (Senior Development Core)

AKRO-PLASTIC expert

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