Potential for your company

seal made of TPU | FFF-process | application: mechanical Engineering

Additive manufacturing opens up new degrees of freedom that can be used in the development process of series parts on the one hand and can have a major influence on the design of the component itself on the other. For example, development processes can be significantly shortened by quickly available and cost-effective prototypes, or components can be developed that would no longer be producible with other conventional manufacturing processes. This results in countless use cases that offer enormous advantages to many areas.

Development

First samples

Probably the best-known use case is the production of design prototypes that are not subjected to mechanical and thermal stresses, in order to check the required component at the beginning of a development in terms of ergonomics, appearance and assembly capability, or to better imagine and compare different ideas.

3D-printed design prototypes can be produced quickly and inexpensively from simple materials, which can drastically shorten the development process.

Functional prototypes

Due to the large selection of materials available, functional prototypes can be produced that are very close to the series part. In many cases, it is possible to process exactly the same material that will later be used in series production as a moulded or milled part.

These additively manufactured functional prototypes are thus mechanically and thermally resistant and can be used in the first series in order to carry out tests in a short time and at low cost.

Test parts for research and development

Additive manufacturing can be used to produce components in order to verify processes and perform simulations. Designs that would not be feasible with other manufacturing processes open up new avenues for research and development.

One example is components with internal channels of different cross-sections, which can even be manufactured transparently to make functions and processes visible.

Suction device made of PET manufactured by additive manufacturing

Suction device made of PET | FFF-process | application: automation

Production and quality assurance

Production tools

Additively manufactured fixtures are ideal for optimizing production steps, avoiding errors or improving quality or making it more effective.

Clamping devices, drilling templates, suction devices, positioning devices for laser marking or manual work steps and grippers for robots can be produced easily and independently of the complexity. At the same time, no production facilities have to be occupied for the creation of these aids. The design of these tools is also very simple, as it can usually be derived directly from the 3D model, without a manually created manufacturing program, for example on a CNC machine.

Assembly tools

Huge potential is offered in the area of assembly stations in the form of additively manufactured holders for components and tools or positioning for manual assembly steps and assembly tools. These aids can be adapted precisely to the requirements and designed specifically for the component. Small quantities, rapid change intervals and complexity do not play a role in the world of additive manufacturing.

Testing devices

Especially in quality assurance, it is important to position the component to be measured tension-free and securely. By means of 3D printing, the fixtures with the exact counter contour of the component can be produced very easily. By using printed plastic fixtures in coordinate measuring machines, the component is not damaged and can be positioned freely in space.

Finished product

We specialize in manufacturing additively manufactured components that can be used in industrial applications. Our process-safe methods, using high-quality materials, are designed to produce mechanically and thermally resilient series parts.

If the additional degrees of freedom offered by additive manufacturing are already exploited in the development phase, entirely new products and solutions can be developed that can no longer be manufactured using conventional methods.

In terms of lightweight construction, geometric complexity and material availability, completely new solutions can be developed.

These can be used to generate decisive competitive advantages.

As a development partner, we stand by our customers and advise them from the very first idea.

Series plastic parts

Complex housings for electronics, load-bearing components made of high-tech materials, hollow components for lightweight applications, complex pipelines and even functioning seals – the possible applications are extremely diverse. Where conventional manufacturing methods reach their limits, additively manufactured components offer a whole new spectrum.

Spare parts

If tool molds are no longer available or defective, spare parts can usually be reproduced in the series material using our 3D printing processes. Only the 3D CAD data is required for production.

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Examples of applications of additive manufactured parts

An additively manufactured large yellow part

Big size 3D printing in motorsport

Thanks 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.

Compact compressed air parts manufactured in additive manufacturing

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.