Additive manufacturing

High-precision and resilient technical 3D printed components for industrial use

You have an idea – we print it out of plastic

Additive manufacturing, known as 3D printing, is a specialized manufacturing process that creates new opportunities for component development.

New degrees of freedom arise in the development of additive manufactured components, which are a great benefit for a wide range of applications. Especially when it comes to complex geometries, lightweight construction or special materials, industrial 3D printing is a real opportunity.

Hänssler helps to exploit these opportunities by establishing itself as a leading service provider and development partner in the additive manufacturing of plastics.

Drive unit made of Ultem 1010 and Iglidur 180 PF I FFF process
PET suction tube I FFF process
Suction device made of PET I FFF process
Plastic carrier made of PEEK I FFF process
Seal made of TPU I FFF process
ABS housing with EMC coating I FFF process
Housing made of PA CF I FFF process | Application: Automation
Compact compressed air distributor made of Resin Clear I SLA process
Elbow made of Ultem 9085 I FFF process
Connecting unit made of PPS I FFF process
Test component made of PA I SLS process
Gear made of PA 6 Ultem 9085 and Ultem 1010 I FFF process

Our 3D printing service goes beyond the additive contract manufacturing of plastic parts. We are a development partner from the idea to series production and support you with our many years of accumulated know-how in the construction and design of industrial 3D printing projects.

We attach a high value to the selection of the most suitable material and its processing parameters.

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Our core expertise in additive manufacturing

personal
contact

development & optimization of plastic parts

selection of
the right material

selection of the right manufacturing process

quality made by Hänssler in Mannheim

responsible production

certified according to DIN EN ISO 9001 (quality)

cross-linked processes

flexible and on-time production

express service possible

personal contact
development & optimisation of plastic parts
selection of the right material
selection of the right manufacturing process
quality made by Hänssler in Mannheim
responsible production
certified according to DIN EN ISO 9001 (quality)
flexible production and delivery in a short time
networked processes
short and exact delivery times

Discover unique technical 3D printing solutions with our experts

large format 3D printing

refined process offers cost-optimized development

Print up to 1 cubic meter in FFF process

Get to know Hänssler’s great 3D printing process. We support you from the first prototypes to small and medium series. By choosing the right material and the ideal design, we manufacture your individual and complex components.

Sustainability and resource savings due to 3D printing

It is particularly worth emphasizing that the additive manufacturing process benefits the environment. Material is saved during production compared to subtractive manufacturing, as only the required amount of filament is used.

Quality and price

Quality, but also prices and delivery times play a decisive role. It is therefore important to make the right choice starting with the semi-finished product. For this reason, we work together with selected and specialized partners.

Fiber reinforced materials

Both glass fiber composites and carbon fiber composites enormously expand the range of applications for additively manufactured components. Fiber-reinforced plastics are the optimal solution, especially when it comes to high load-bearing capacity, dimensional stability and maximum weight reduction.

Heat resistant plastics

Plastics are often not considered for high-temperature applications, although a large number of heat-resistant plastics are now available. Combining the other advantages of these heat-resistant plastics, such as low friction, low weight and chemical resistance, results in technically interesting solution possibilities.

Post-processing of 3D printed parts

In principle, additively manufactured components or 3D prints can be used without further processing steps. However, additively printed components can be optimized for certain applications. There are different processes available for this process, and specific advantages of conventional and additive manufacturing methods can then be combined.

Potential for your company

Additive manufacturing opens up new degrees of freedom that can be used in the development process of series parts on the one hand and have a major influence on the design of the component itself on the other.

3D printing food compatible

Fast, cost-effective and food-safe 3D printing is supposed to deliver urgently needed components – even in small quantities. But do the material and the 3D printing process even meet the high requirements of the food industry?

Additiv gefertigtes Bauteil in der Prozessüberwachung

Process monitoring in 3D printing

Today, hardly any common manufacturing process is imaginable without process monitoring. This guarantees reproducible conditions and thus consistently high quality. Industrial 3D printing at HÄNSSLER is now also constantly monitored.

Absaugrohr aus PET | FFF-Verfahren | Einsatz: Automatisierung

Manufacturing processes

The terms “additive manufacturing” or “3D printing” include a wide variety of manufacturing processes. Depending on the requirements, e.g. in terms of material, accuracy or quantity, we select the best possible process for the specific application.

Big size 3D printing in motorsport

Due to the new manufacturing possibilities offered by our new large-format 3D printers with a build volume of up to one cubic meter, we can produce the shape of the new carbon rear wing in one piece. Recycled PET was chosen as the material, which saves costs and weight.

SLA 3D printing process in practice

Whether customer project or internal improvement of the machinery, Hänssler develops functional prototypes up to small series. This means that special machine parts or complete machines can be designed in-house. The manifold with several pneumatic connections shows what is possible even in the smallest installation space of approx. 4×4 cm.

Low volume 3D printing: 300 components as thermal protection

To complement a machine, it was necessary to develop a component with anti-electrostatic properties. This had to consist of two different components to make it easier to install and remove.

Mehr erfahren

Air conditioning of the Hänssler machine park

Our production possibilities range from turned and milled parts, turned-milled parts on state-of-the-art machining centers, to 3D printing components in a wide variety of manufacturing processes. In order to be able to offer our customers the highest quality, we are constantly expanding our know-how in order to optimize manufacturing methods and processes.

Materials

Here we present our available materials that are used in additive manufacturing. For each material, you will receive information on its properties and possible applications.

Material gallery

Material table

FAQ

Up to what size is 3D printing possible at Hänssler?

We print your components up to a size of 1000 x 1000 x 1000 millimeters. If larger dimensions are required, we can realize them by assembling printed elements. We use screwed or glued connections for fixing.

How long does it take to 3D print one or more components?

This is highly dependent on the material used, the size of the component and the strength of the component later on, as well as the process used and the printer which is required. Depending on the process and component size, it is possible to produce several parts in one printing process. Our engineers specialized in this field will be happy to advise you.

In which file format should the data for 3D printing be delivered?

We prefer to receive STEP files. From these, we generate the print files required later in STL format. This brings benefits for the manufacturing process and for you as a customer, because the later quality of a component depends mainly on the optimal file.

What are the usual tolerances in 3D printing?

This depends on the material used, the geometry of the component, the 3D printing process selected and the printer used – and should be checked on a case-by-case basis. As a general rule, production is carried out in the range 0-10 millimeters according to general tolerances DIN ISO 2768-1 c, and from 10 millimeters according to general tolerances DIN ISO 2768-1 m. If more detailed measures or optimized surfaces are required, the components can also be reworked on a CNC machine in the post-process.

Is 3D printing only suitable for prototypes or can the components also be used?

Hänssler offers 3D printing in industrial quality. In concrete terms, this means that our components are used in practice day after day, even under constant load. Our 3D printing engineers will be happy to work with you to find the right materials and manufacturing processes.

Is 3D printing also ideal for the production of larger quantities or series?

Definitely! In addition to unique pieces and prototypes, we produce not only small series for our customers, but also series of medium quantities. In a user story, we report on the successful series production of 300 components using 3D printing.

Does Hänssler also offer 3D printing for medical, pharmaceutical, food technology, etc.?

We process a variety of materials additively. We will be happy to work with you to find a technically suitable and compliant material for your demanding application.

Is it possible to manufacture seals using 3D printing?

For example, we print seals and sealing lips from the elastomer TPU in Shore hardness A 95, some of which are difficult or impossible to produce by conventional means. 3D printing also performs well in sealing technology, especially when it comes to small diameters.

Can 3D printing be used to produce molds?

In principle, yes. Especially for concrete casting or casting resins, individual molds can be designed with manageable effort. 3D-printed components are also used as negative molds for laminating molds. Please also read our user story. With all processes, it should be noted that the surface should be covered after 3D printing in order to be able to remove the molded component from the mold.