ARBURG Plastic Freeforming - mpma.org.my Paper Arburg revised.pdfIn order to produce a rigid, high...

$: ARBURG Plastic Freeforming - mpma.org.my Paper Arburg revised.pdfIn order to produce a rigid, high quality part, we do it as following:-\爀屲As expertise in-house, yesy, we have$
ARBURG Plastic Freeforming

Lim Wei Yen / Manager for Additive Manufacturing

New Industrial Additive Process

Presenter

Presentation Notes

Self Introduction

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

2 © Copyright by ARBURG 2015-09 / MPMA Conference – 3D Printing / KL

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


ARBURG Plastic-Freeforming

Agenda • Introduction

• Technology: freeformer and plastic-freeforming

• Material and Properties

• Examples of application

• Summary and future targets


Introduction

Market requirements are changing

Short product lifecycles

Rapid technical development

The desire for customised

products

Increasing variety of

product versions


Presenter

Presentation Notes

Maybe you know, maybe you don’t know. ARBURG is producing injection moulding machines. ARBURG produces thousands of machine every year. Why do we look into additive manufacturing? When we look closely to the market, there are trends that the customer is working with - shorter product lifecycles (e.g mobile phones, consumer electronics, etc..) Increasing the variety of product versions customisation We are thinking how can we effectively and efficiently produce one or two parts or even small batches Usually in traditional methods, it takes time and cost to rapid prototype a product and by the time it is finalized, the design has obsolete. So it would be nice to have the prototype in a few hours or at least over night. Or even with the technology now that there are a lot of additive manufacturers out there, but the material cost is too high. What we saw is that to get a faster part onto my table, even functionalble, with mechanical strength and having the part overnight. And the solution for that is basically additive manufacturing

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

© Copyright by ARBURG 2015-09 / MPMA Conference – 3D Printing / KL

Presenter

Presentation Notes

Now your designer will design a new idea a new concept and produces a CAD file. Exporting the file as STL and load it into the software on my laptop or computer. The software is doing the slicing into layers and the software is creating the NC code like in the CNC machine. We in turn load it into the machine via USB or LAN connection and we start the machine running. The data preparation is done on an offline computer, the machine is only for adjusting of mechanical movements and also injection parameters.

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


Presenter

Presentation Notes

In order to produce a rigid, high quality part, we do it as following:- As expertise in-house, yesy, we have a good know-how of how to melt material, how to deal with different resins. We use standard granulates There is a 15mm screw which is melting the material. Video: Like said the data preparation is done on an offline computer not directly at the machine. While the machine runs I can prepare the second or third job. 3) We have here the check ring (non-return valve) on the screw. Similar to injection moulding. 4) Then we close the check ring and we slowly release small tiny droplets 5) There is this yellow part which is something like a shut off needle mechanism, this needle gets push up by the melt pressure building up, the needle opens. We are working with about 200-600bars for the melt presssure. 6) On top we have a quartz piezo that acts as the closing mechanism. It is similar like a diesel injection engine from the principle point of view. 7) We do first the outside border line at about 40 to 60 Hz. Slower for better surface quality 8) Then the filling at about 150 to 200Hz Speeding up the process. 9) Using this layering process, this is repeated till the part is finished. 10) To get a good bonding part, the process chamber needs to be heated up. *pass parts around.


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


Presenter

Presentation Notes

*Play video for 2K Basically this is the principle behind the process. After this principle, we have tried to figure out the three main features of this new machine.


Influence factors • Surface quality:

droplet / nozzle size

• Density: Material, filling strategy and processing parameters

• Mechanical properties: processing parameters e.g. chamber temperature

9

Homogeneous and dense layer


Presenter

Presentation Notes

1st feature The question: Why do we use droplets? Unlike the FDM or deaktop FFF process they are making strings. We are dispensing droplets because we want to have Give a better/closer connection A more homogenous layer Better mechanical properties Due to the fact that this is an open system, we are able to adjust the process in how close we want the droplets binding together.


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


Presenter

Presentation Notes

Fine and slow Fast but rough 0.15mm 5g/hr 0.25mm 20g/hr


Integrated material preparation • In principle all unfilled

Standard/customer- specific granules

• Good material availability

• Specific dyed material

• More cost efficient use of material


Presenter

Presentation Notes

Second feature As you have seen other AM machines, there is a need for special materials, materials that are modified in order to work in their machine. Here we use standard plastic granulates Good Availability of the materials choice of colored material is possible Low material cost.

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


Presenter

Presentation Notes

We have qualified four commonly used materials ABS, TPU, PC and amorphous PA12 And we will spread our wings and go into Polyamide Nylon 6 and also PP. We have done applications but it is not completely fulfilled yet. The philosophy behind this. It is yes, an additive manufacturing machine. But as a customer, they are and will be in the driver seat. You can use materials as used in injection moulding. BUT (restrictions) As of now we do have a few restrictions to the material: We create tiny droplets and we need to get the material through the nozzle. Filled materials like glass/carbon fibre will actually block our nozzle Behind the curtains we are working on a solution to get glass fibre working. As of now, it is not possible to produce glass filled materials. Feature number three! We want to have an environmental and user friendly machine First of all the machine only needs one electrical power source (3-phase) No compressor needed, no chiller needed. No dust, no emissions, a very clean machine We also have centralised control system. The standard material settings are given as pre-settings in the machine, and we only need to press a few buttons to start a job running. We also realised that there will be customers that have proprietary material and wants to run them in the machine. We can do that because the machine runs on injection moulding technology and this is an open system. Meaning adjusting the process to the user.


Application example: tensile test samples


Presenter

Presentation Notes

What do we actually achieve in terms of tensile strength


1 mm

Tensile tests for Terluran GP 35 (ABS)

Additive manufacturing

Moulded


Presenter

Presentation Notes

Here is a comparison of the tensile bars. The injection molded tensile bar looks compact because of high injection pressure And interestingly with the freeformer we are in the range of about 80% as compared to the injection moulded part. As you can see from the graph that the part reaches the peek as of the moulded part and breaks off. That is obvious because we are forming only with droplets, not like the injection moulded part with high speed and high pressure.

15

Tensile strenghts APF ABS Terluran GP 35

Comparison to Injection Molding

15

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



Presenter

Presentation Notes

It is not possible for Arburg to qualify ALL materials as we are talking about tens of thousands of raw materials out there in the market.

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


Presenter

Presentation Notes

We have the two component version: Hard soft Different colors (no support needed) Or Support material

Small scale production and function integration


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



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


Complex geometries using support structure


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



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


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


Presenter

Presentation Notes

Drop by drop for high dense parts Parts produced by the freeformer has less internal stress due to the speed and pressure is not that high as compared to injection moulding. Parts are flatter,I have tried doing a very thin mobile housing, which shows warpage with most process but it is flat using the APF. No sink marks Properties are close to injection moulding Very important, OPEN SYSTEM!


Extended process: Five-axis component carrier

22

Two additional rotary axes

© Copyright by ARBURG 2015-06 / Studienamiddag rond extrusion based additive manufacturing: technologie en materialen / Heverlee

Complex geometries without support structure


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


ARBURG Plastic Freeforming

Lim Wei Yen/ Manager for Additive Manufacturing

New Industrial Additive Process

ARBURG Plastic Freeforming - mpma.org.my Paper Arburg revised.pdfIn order to produce a rigid, high...

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