The new 3-D printing resin from igus enables the additive manufacturing of the smallest wearing parts, with a service life 60-times longer than standard resinsiglidur i3000 from
igus is the world’s first resin formulated specifically for DLP (Digital Light Processing) 3-D printing of parts subject to wear. This enables the additive manufacturing (AM) of particularly small and precise components with a service life 30- to 60-times longer than conventional 3-D printing resins. At the same time, igus is expanding its 3-D printing service to include DLP printers that achieve a resolution of 0.035mm.
For making components at the millimetre scale, 3-D printers that use the DLP process are particularly suitable — the process achieves a very fine resolution among the various 3-D printing technologies. Resolutions of just 0.035mm — about half as thick as a human hair — are possible.
To achieve this, a projector emits layer by layer of the 3-D model onto the surface of a special liquid resin which connect and fuse under the influence of light. After curing a layer, the build platform is lowered by a single layer for the next exposure. Layer by layer, tiny components are created, for example gears whose tips are only 0.2mm thick and which have an extremely smooth surface and do not require post-treatment.
With the new 3-D printing resin iglidur i3000-PR, customers can now benefit from igus’ tribo technology and thus greatly increase the service life of their moving application.
Dean Aylott, product manager for 3-D printing at igus UK, said: “A common problem with DLP 3-D printing is that tiny components made of commercially available 3-D printing resins, such as gears for model making, are not particularly robust and can fail quickly.” This was the driver for igus to develop iglidur i3000 for DLP 3-D printing, which is tribologically-optimised (lubrication-free) and thus more wear-resistant.
He added: "We were able to prove in laboratory tests that the service life of iglidur i3000 is at least 30-times longer compared to 10 commercially available 3-D printing resins. In some applications, we even expect an increase in service life by a factor of 60.”
Another advantage is the low maintenance, as there is no oil or grease to replace. Microscopically small solid lubricants are integrated into the material, which release independently during movement.
Tiny special components produced quicklyIn addition to 3-D printing resin, customers can order components made from iglidur i3000 directly from igus. While customers were previously able to choose between the selective laser sintering (SLS) and fused deposition modelling (FDM) 3-D printing processes, now they will also be able to order components manufactured with DLP 3-D printers. The finest details and even inner channels can be easily produced.
Mr Aylott concluded: “We have now started the beta test phase with our first customers and are also working to ensure that DLP 3-D printing is also available in our online tool that allows users to upload STEP files of their components, or to configure gears with just a few clicks.
“Thanks to the combination of 3-D printing and online configuration, weeks of waiting time for wear-free special components has been consigned to history. In 2021, igus produced more than 200,000 3-D printed abrasion-resistant components in Cologne, in quantities of one to 10,000. When there are bottlenecks and disrupted supply chains, 3-D printing is now a real and viable alternative.”