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3D printing in manufacturing at ROBOWORKER

Last year, ROBOWORKER invested in the expansion of its 3D printing capability and converted part of the production hall into a 3D printing center. Under the direction of Johannes Sonntag, design engineer at ROBOWORKER, not only prototypes and machine components are created here, but also pallets and accessories that are perfectly adapted to the requirements of our customers. In the following interview, Johannes tells what fascinates him personally about 3D printing and what new possibilities and advantages this technology offers ROBOWORKER and our customers.

Interview with design engineer Johannes Sonntag

 

  1. Johannes, what fascinates you about 3D printing?

As an engineer, I find the vast opportunities of 3D printing very exciting. The new design options and the high degree of freedom in the manufacturing of components allows for completely new ways of thinking in engineering and helps finding new solutions to complex technical challenges.

  1. How has 3D printing evolved at ROBOWORKER? Where did we start and where are we today?

We have been using 3D printing for quite some time now at ROBOWORKER. In 2005, we started experimenting with 3D printing, which was a rather new technology at that time. Today, we use three different 3D printing technologies: the fused layer process or fused deposition modelling (FDM), the stereolithography process (SLA) and the selective laser sintering process (SLS). Each procedure has its advantages. This means that we can select the technology according to the respective area of application of a component.

  1. When should a firm use additive manufacturing to create production parts?

As soon as you cannot solve a problem with conventional manufacturing technology, you almost automatically turn to 3D printing for solutions. Since we are specialized in automation, the possibility of manufacturing lightweight components is a great advantage. For instance, heavy covers that were previously made from stainless steel sheets can now be replaced by a thin-walled plastic part. Moreover, 3D printing is the ideal technology for small-scale manufacturers like us because it is not worth producing an injection molding tool for small quantities. However, 3D-printing allows us to incorporate design changes to a component at any time, because we do not need to change injection molding tools first. Instead, we simply use the new data set of the model. Everyone who works in mechanical engineering benefits from this technology.

  1. What are the advantages of 3D printing for manufacturing?

In general, 3D printing is a more resource-efficient form of production. For example, we try to produce the parts with a reduced volume. This doesn’t prevent us from making more solid components when needed, e.g. for load reasons. Another important reason is that a certain proportion of the used powder in the SLS process can be returned to the process.

  1. What opportunities does 3D printing offer designers?

Design freedom is a key advantage. Just think of internal, curved air ducts that could not be produced with conventional technology. Another advantage is the possibility to manufacture several parts in one component (assembly consolidation). It increases efficiency by reducing for example the variety of parts and assembly time. The further development of the constructive way of thinking, new solution approaches, innovations and bionic designs show further possibilities.

  1. How does 3D printing affect product development and time to market?

By using this technology, we can significantly accelerate product development and thus shorten the time to market. If need be, we can produce a newly designed part within a few hours using FDM or SLA technology.

  1. Why is it worth investing in expanding our 3D printing area?

This allows us to better exploit the potential of 3D printing. If you have such a technology in-house and understand the technology and the process exactly, you can also optimally skim off all the advantages.

  1. What are the printed parts used for?

There are many uses here. Particularly important for us are the perfectly customized pallet systems with ID, accessories and equipment that can significantly improve our customers’ manufacturing processes and that seamlessly work in their systems. In addition to that, we use housings, covers, holders, suction or blow-off nozzles, gripper jaws, suction pieces, adapters, parts with snap connections etc. for the ROBOWORKER systems, to name just a few examples.


How is the durability?

The polyamide used in the SLS process is a very robust thermoplastic material that is very stable over the long term. It can replace injection-molded parts and has proven itself in practice. This is also used in automotive engineering, aerospace and in the consumer goods sector. In addition, the material is biocompatible and food-safe and suitable for various parts in medical technology.

What are the advantages of this for ROBOWORKER and our customers?

We can respond to customer or internal requests immediately. Prototypes are manufactured very quickly, which means tests can be carried out immediately. In this way, you receive feedback as quickly as possible and can use this to initiate further measures. This is very efficient and saves time for us and our customer.

What do you think the future of 3D printing looks like?

A lot will change in the production processes. Milling, gluing and casting processes can be supplemented using 3D printing. This reduces energy costs, raw materials and waste. 3D printing is now even being used in other industries such as construction. The first houses have already been created using a printer adapted to a liquid building material. Such a printer is installed on site at the builder's property and builds the walls of the house layer by layer. Due to automated processes and ever faster printing methods, 3D printing is becoming more and more the standard technology for series production.

 

More information about our 3D offerings will follow soon.

 

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