3D printing manufacturing process

Suction pipe made of PET | FFF process | Application: automation

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

To identify the optimal process, it helps us a lot if we know the application of the component. Interesting parameters are e.g.:

operating temperature
mechanical load
required exactness
media contact
required weight

In many cases we have the possibility to process the identical material to be used in further development steps or in series production.

Overview of the most important manufacturing processes

In the field of 3D printing, there are many manufacturing processes and many different materials. From this variety of combinations, we can define the optimal implementation for your application. We rely on the manufacturing processes FFF and SLA.

Another benefit is the combination with our conventional manufacturing processes; this means that additive manufactured components can be reworked in our plastics technology area if required.

We can produce prototypes in a wide variety of manufacturing processes and materials:

FFF process
SLA process

We will be happy to advise you on suitable manufacturing processes and ideal materials for your application.

FFF-Druckverfahren der additiven Fertigung

Fused Filament Fabrication

The FFF process, also known as the FDM process from the Stratasys company, is probably the best-known 3D printing process. A plastic wire (filament) is fed into a heated print head. There, a nozzle melts the filament and applies it layer by layer to the build platform.

FFF is considered one of the most cost-effective 3D printing processes with a very wide range of materials at the same time. We have specialized in processing especially high-tech materials for high mechanical and thermal loads with this process.

High diversity of materials
Hollow and thus very light components can be manufactured
Cost-effective for small and medium quantities
Minimal material consumption, particularly interesting for high-quality high-tech materials
Suitable for the production of load-bearing components
Medium accuracy, but can be improved by mechanical rework
Longer manufacturing process
Textured surfaces in layer direction
Mechanical load capacity in x, y and z different

SLA-Druckverfahren der additiven Fertigung

Stereolithography

The SLA process is the oldest patented manufacturing process. In this process, a liquid synthetic resin is cured layer by layer by a laser. This process can also be used to process different materials with special properties.

Components with special requirements in terms of accuracy and optical demands can be manufactured with it.

Very high precision
Very high surface quality
Large variety of materials
Filigree geometries can be produced
Elaborately reworking
Final product not permanently UV resistant
No hollow, closed components possible
Materials not available in other manufacturing processes

SLS-Druckverfahren der additiven Fertigung

Selective Laser Sintering

By means of a laser, the desired material is melted in powder form, layer by layer, and the individual layers are bonded together in the process. The variety of materials is somewhat limited with this process.

Especially for the production of higher quantities, this process can offer an economical alternative.

Suitable for the production of load-bearing components
No support structures necessary
Low-cost series production
High precision
nefficient for small quantities
Surfaces slightly textured
Limited choice of materials

Versuchsbauteil hergestellt in additiver Fertigung

Test component made of PA | SLA-process

Kompakter Druckluftverteile aus Resin Clear hergestellt in additiver Fertigung

Compact Compressed Air Manifold made of Resin Clear | SLA-process | Application: automation

Examples of applications of additive manufactured parts

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.