APF. ARBURG Plastic Freeforming.

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1 APF ARBURG Plastic Freeforming

2 APF

3 industrial additive manufacturing A look at industrial additive manufacturing from the point-of-view of a machine manufacturer: This involves a practical approach, many new solutions and an innovative, patented process - ARBURG Plastic Freeforming (APF). In other words: a completely new approach! Additive manufacturing. With qualified standard granulate and layers built up from tiny droplets of plastic. 3

4 Process principle Using the freeformer, a machine developed specially for the APF process, we melt the granulate in a process similar to injection moulding involving integrated material preparation. A heated plasticising cylinder with a special screw produces a homogeneous plastic melt. The special discharge unit featuring a pulsed nozzle closure marks a new era in industrial processing: A nozzle closure controlled by high-frequency piezo technology enables extremely rapid opening and closing of the nozzle. Depending on the nozzle size, plastic droplets with a diameter of 0.15 to 0.34 mm are generated in this manner. The moving part carrier is positioned via servo motors so that each droplet is placed on the precise point previously calculated. No special processes or material additives are required in order to harden the plastic in the temperaturecontrolled build chamber; instead, the tiny droplets bond together automatically as they cool. This enables us to build three-dimensional plastic parts layer-bylayer without requiring moulds or fixed cavities. Moreover, the processing of materials without emissions or waste is an interesting feature of our APF process. The freeformer does not require an active extraction system. A high degree of processing flexibility was a further key objective taken into account during the development of the APF process. This is why we deliberately designed our freeformer as an open system. Tiny plastic droplets provide the basis for flexible adjustment options. The droplet size and process control can be influenced in a targeted manner. This gives you the freedom to individually optimise the properties of your additively manufactured parts and to process a wide range of original materials. Furthermore, our freeformer features several discharge units as standard. You can use these to produce functional components in various materials and colour combinations also as durable hard/soft combinations. Self-dyeing is possible in master batches. In the case of complex part geometries, you can alternatively use one component to build up support structures. 4

5 Basis: Qualified standard granulate Piezo actuator performs nozzle closure Nozzle closure Material preparation via screw as with injection moulding Material reservoir between screw and nozzle tip is under pressure Discharge of individual droplets from the nozzle tip The part carrier moves the part along the X and Y axes and step-by-step downwards along the Z axis 5

6 6 APF

7 Materials and properties ARBURG Plastic Freeforming means entering into a completely new technology. Our freeformer can manufacture individual one-off parts and small-volume batches using qualified standard granulates. No injection mould required. Parts created directly from 3D CAD data. With an open system that permits individual process optimisation and qualification for your own materials. Tap into a whole new range of options for industrial additive manufacturing! 7

8 In the APF process, a slicer software is used to prepare 3D CAD data (STL format) in layers for the machine-specific requirements. You can then use our freeformer to build your part dropby-drop, layer-by-layer, from qualified standard granulates. Individualised, yet cost effective. Without the aid of a mould. From single-unit batches upwards. This starting point offers a host of interesting options: Material variety no prefabricated materials, no manufacturer-dependent procurement Use of original materials e.g. to ensure resistance to ageing Moulded parts can be additively individualised, e.g. through the combination of injection moulding and additive manufacturing The APF process allows standard granulate and support materials to be processed in a flexible way. However, reproducible additive manufacturing requires the materials used to be qualified. The result of this qualification process is optimised process data, which includes all the important settings according to quality and materialdependent criteria. Beginning with layerby-layer geometrical slicing to automatic processing of the 3D CAD data to generate an NC program, through to the processing temperature and discharge of the droplets. Basis: 3D CAD data in STL format Slicing and generation of the NC program freeformer: layer-by-layer build-up of parts from droplets Finished part 8

9 Our material database for the APF process is growing continuously and now includes process data for numerous materials. These include: Standard additive material types such as ABS, PC, TPU and PA (amorphous) Blends of these materials, e.g. PC-ABS Special original materials such as PP and PE (semi-crystalline), PEI (high temperature resistance), flame-proof materials, medical polylactide or biopolymers Water or alkaline-soluble support materials, compatible with the build material The open system of the freeformer ensures that all slicing and process parameters are always freely programmable. This enables you to optimise processes and material qualification on an individualised basis, for example for certain additive processes or colour schemes. However, as with injection moulding, this requires some knowledge of plastics processing. Here, our expert technical advice will help you every step of the way. The part quality achievable with APF displays a particularly even and close structure - in every direction. The density, material properties and surface structure can be influenced in a targeted manner by varying the droplet size and process control. The more densely the droplets are positioned in relation to one another, i.e., the more tightly the parts are packed, the higher the mechanical properties. Computer tomography image of a part produced using the APF process: homogeneous, densely structured layers. Studies have shown that, depending on the material type, the same tensile strengths can be achieved in the layers as is the case with injection moulding. 9

10 APF

11 in practice Our innovative APF process enables you to combine design freedom with a wide range of materials. In this way, you can quickly produce spare parts or functional samples from the desired qualified material, for example. Whatever industry you may work in, the freeformer offers you a wide range of new options: from consumer goods and automotive parts through to medical technology - to name just a few examples. Complex geometry: the elastic bellows made from TPU is produced with the help of water-soluble support materials. 11

12 One-off parts and small-volume batches Cranial bone implant Material: medical PLLA Layer thickness: 0.27 mm 70 spacers for ALLROUNDERs Material: PEI (Ultem 9085) Layer thickness: 0.15 mm Functional integration Cable clips with click-effect Material: PP Layer thickness: 0.21 mm Toothbrush with flexible head Material: ABS Layer thickness: 0.21 mm Cable pulley produced as assembly Material: Biopolyamide Layer thickness: 0.27 mm 12

13 Multi-component technology Gripper finger Material: PA10 +TPE (80 Shore) Layer thickness: 0.21 mm Gripper with sealing lip and integrated air channels Material: ABS + TPE (80 Shore) Layer thickness: 0.21 mm Individualisation Further examples Office scissors with additively applied 3D lettering Material: PP Layer thickness: 0.21 mm Rocker-type light switch with additive 3D finishing Material: ABS + TPU Layer thickness: 0.21 mm 13

14 Free for Work safely. Free from dust and emissions. Make efficient use of materials. Without waste. Combine different materials. Without problems. 14

15 greater efficiency First we continuously perfected injection moulding. Now we are developing industrial additive manufacturing. Our objective has always remained the same: quality at affordable unit costs. We believe there is a great deal of potential for the future in this. Process and parts Individually optimisable. Without limitation. Qualified standard granulates or process your own materials. Without prior preparation. Produce fully functional parts. No injection mould required. 15

16 APF more than just 3D printing: Plastic products from qualified standard granulate Broad range of processable materials Individual part optimisation and material qualification High-grade mechanical properties Efficient use of materials ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com _EN_GB_ Subject to alterations Printed in Germany