China3D printingNet news on August 3,3D printingOne of the many holy grails is the ability to 3D print fully functional objects in a single build process. The multi-material processes of companies such as Inkbit and Sakuu are pursuing such goals. However, it may not require new 3D printing methods like them to produce functional objects such as electronic devices. A research team at the Additive Production Center of the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) demonstrated the ability to manufacture sensors using ARBURG’s single-material deposition technology.
The team of Fraunhofer IPA produces inductive proximity sensors directly in their housings. These cylindrical devices usually consist of a coil, a circuit board, and a plug in a metal housing. They can be used to measure the distance of metal objects in industrial manufacturing and other applications. However, due to the standard and mass-produced shape of sensors, they are not always perfectly adapted to a given environment.
The ability to 3D print complex multi-material products has many benefits. In addition to reducing labor steps, additive manufacturing (AM) of such items can also enable mass customization of electronic products or complex geometries, thereby improving the performance of the equipment. For example, by directly integrating smart phone batteries and antennas into its polymer housing, the phone can become smaller and lighter, while increasing energy density or communication range.
The Freeformer sizes 200-3X and 300-3X can process plastic pellets and are also used for injection molding. Image courtesy of Arburg.
For proximity sensors, Fraunhofer IPA suggests that one can be directly integrated into the robot’s gripper for smarter processing of items on the production line. To prove this possibility, the Fraunhofer team worked with ARBURG’s Freeformer 3D printer and automation company Balluff GmbH, which uses a proprietary method to melt plastic particles and deposit them on the printing bed.
It is necessary for researchers to use plastics with high dielectric strength and flame-retardant properties, which led them to use plastic polybutylene terephthalate (PBT). Although PBT is a standard injection molding material for electronic housings, it is not used for 3D printing. Here, ARBURG is able to demonstrate one of the advantages of Freeformer, which can process injection-molded pellets on plastic filaments, so a wider range of materials can be used.
Fraunhofer IPA’s 3D printed sensor, including coils, circuit boards and plugs in plastic housings. Image courtesy of Fraunhofer IPA.
The team 3D printed the parts, leaving openings where external components could be integrated during the manufacturing process. The machine is programmed to stop when necessary so that coils, circuit boards and plugs can be inserted into printed parts. At the same time, the distributor applies a silver conductor track inside the housing. After completing these steps, Freeformer will print on the opening.
Fraunhofer created a total of 30 custom sensors and ran them in a standard operating environment, demonstrating their ability to withstand changes in temperature and vibration. These devices are also waterproof and can pass electrical insulation tests. The project is called “Electronic Function Integration in Additive Manufacturing Components” and lasted 18 months. The team is currently working with ARBURG to explore further uses of conductive plastics.
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