3D printing customer application examples

The Shanghai New GOOD Packing Machine Co., Ltd. relies on 3D-printed positioning bars made of iglidur i150 in its cartoning machines. The solution from the 3D printer is up to 75% more cost-effective, 85% lighter and also available much faster than the previously used milled aluminium alternative.

Timing screws are a central component in packaging and filling technology. They are used to separate containers such as bottles and cans at a defined distance and feed them into the machine in a synchronised way. 3D printing is a lightweight and durable alternative to conventionally milled worm gears.

Product turners made of wear-resistant iglidur i150 filament enable the precise turning of cans, jars and tins in conveyor belt systems. They are designed for reliable continuous operation in industrial applications.

Stausberg & Vosding GmbH relies on 3D-printed gripper fingers for its pick-and-place system. The flexible solution is more durable and cost-effective than milled grippers and can be ideally adapted to complex bottle geometries.

For repair of the roof-mounted water cannons of airport fire-extinguishing vehicles, the maintenance technicians of Fraport AG found cost-effective replacement parts in the form of printed gears made of iglidur i3 that satisfied the high load-capacity requirements.

Standby GmbH needed suitable durable gears for the small stepper motors in its newly developed searchlight mounted on emergency vehicle roofs. The wear-resistant 3D-printed gears made of iglidur i3 have proved to be the most suitable for this purpose.

High concentrations of the protein troponin in the blood indicate possible heart attack. To measure concentrations precisely, a stepper motor rotor has to achieve an angular displacement of less than 0.1 degrees. 3D-printed gears made of iglidur i3 play a decisive role here.

3D-printed clamps from iglidur i151 ensure precise microscope camera panning for real-time recording of the electrical micro-component printing process.

A 3D printed gear improved tolerances and ensured smooth "floating".

Modern DIY motion simulators generate loud operating noises. How can 3D-printed igus sliding components greatly reduce mechanical simulator noise? Find out more in the following use case.

With igumid P190, a special mounting bracket for the igus energy chains could be produced, which enables a more compact design of the large-format 3D printer and thus saves space and money.

A device was manufactured from iglidur i190 in 3D printing so that drylin rails will rest at right angles on a profile saw's working surface. An optimal solution for precise cutting of large orders.

The complex special slider was urgently needed on the construction site in the Thyssenkrupp testing tower. The igus 3D printing service was able to deliver it within 48 hours.

A complex bevel gear was required for the drive unit of a dispenser. The dosing unit's small installation space meant that only 3D printed components could be used, since they were able to meet the complex geometry and requirements.

To allow long exposures in astrophotography, a device with a gear and motor was developed to counteract the Earth's rotation. The iglidur i150 gearbox ensures precision and stability.

Light, detailed and resilient - the Technische Hochschule Zurich (ETHZ university) uses finger joints made of iglidur i6 for the speedy manufacture of tailor-made hand exoskeletons.

With igus components, it was possible to develop an ejection mechanism that helps to collect real data on the movement and position of objects in space and thus remove space debris.

The steering system of the 3D-printed vehicle had too much clearance and quickly became inaccurate. Strong and precise steering was guaranteed with ball bearings made of the tribofilament iglidur i150.

"The 3D-printed component made of iglidur impressed us with its quality, stability, strength, dimensional accuracy and the running properties between the shaft end support and lead screw." Project team of the Ansbach School of Mechanical Engineering.

In order to ensure easy and sustained adjustment of an innovative rear spoiler, parts made of tribologically optimised iglidur polymers are used at the support points on the wing so that low-friction and maintenance-free adjustment is possible.

A plain bearing broke in a WAREMA Sonnenschutztechnik GmbH moving rack, causing a delay in production. With 3D-printed prototypes made of iglidur i3, a new split plain bearing was designed that enables faster replacement.

To make the igus energy chains more durable, adapter clips for the transition between glide pad and chain were developed. The adapters made of iglidur i6 were printed and tested together with the 3D printing team. Conclusion: "Comparable to injection moulding."

Thanks to the tribologically optimised iglidur i150 filament, components in the movement that are exposed to very high mechanical loads were able to achieve a significantly longer service life and a more regular running of the escapement than parts made of conventional PLA.

A classical grand piano has been fitted with new hammers made of iglidur i3. Pianists who have tested it say it's "like swapping an Austin Seven for a Ferrari".

"That works like a well-oiled machine - only better!" The broken gear of a tractor used by igus was reverse-engineered and printed within a few hours.

By replacing the standard plastic bearing with a 3D-printed model made of iglidur i3, the pram no longer needs to be lubricated and runs smoothly.

As the manufacturer was unable to supply spare parts for the gearbox of his e-bike, the customer had igus print gears made of iglidur i3. The result is improved performance and complete satisfaction.

Even after more than 2,000 miles of use in a classic car, the customer could not detect any wear on the reproduced intermediate shaft with gear wheel made of iglidur i6.

Robust pinion with special dimensions delivered in less than 72 hours. iglidur i6 in use in a racing car as a chain tensioner in the chain drive.

"A high degree of flexibility and fast delivery times are crucial when it comes to prototype construction. It is exactly these specifications that we like about using the igus online configurator to select gears from a wide variety of different types and have them printed quickly. Easelink founder Hermann Stockinger.

50% cost reduction, delivery within a few days, improved sliding properties and longer service life. The spare part made of iglidur i3 improves the machine and reduces costs at Conti Tech Schlauch GmbH.

The cost-effective and fast manufacture of small volumes of abrasion-resistant special parts persuaded the company Kempf to use sliding elements made of iglidur i3 in its 'Darios' accelerator ring.

Replacement parts made of iglidur i180 are 15 times more cost-effective than the special metal sliders previously used by the customer and can be delivered within a few days.

The standard metal pinion generates a lot of noise when in use. After two months of use in two wheels , the replacement part made of iglidur i3 has reduced the noise output considerably.

Due to the changeover from aluminium to 3D printing with iglidur polymers for the production of grippers, Carecos Kosmetik GmbH was able to reduce costs by up to 85% and manufacturing time by up to 70%.

For a fully automated drive-in corona test station, the gripper of the robot arm was manufactured from iglidur i3 using laser sintering. This reduces the load on medical staff.

An urgently needed replacement bearing for a camera dolly was printed and handed over to the happy customer within only a few hours.

A customer needed a new rudder bearing for his sailboat. He summed up the experience as follows: "For me, it was a perfect example of how Industry 4.0 works. It took just three weeks to move from the task to the real-world solution to a highly customised design problem, and only two hours were on the computer."