New 3D printer

Faster to the automotive plastic component

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On the way to 3D printed parts with injection molding quality

However, more than a year will pass before the aforementioned goal is possibly achieved, as the researchers admit. They are currently working toward the optimal process parameters. To do this, the IPA researchers begin with simple components that are manufactured with increasing accuracy and quality until the necessary quality is reached. Then they take the next step in terms of complexity. For this, they also use the new industrial 3D printer, which offers a comparatively large build space. Developing suitable process parameters for processing new plastics is particularly important for this. In parallel, it is being tested with project partners how the sensor can be used to monitor the laser process. With the data collected by the sensor and the machine data that the 3D printer offers as standard, an AI model is to be trained. And the more plastic components are manufactured, the better the artificial intelligence (AI) understands what the best process parameters are and how deviations affect product quality, as explained.

The digital process chain for additively manufactured plastic parts

All of this is happening as part of the "DigiAutoFab" research project, which began in late summer 2023 and will run until June 30, 2026. The goal is to forge a fully digitized process chain for additively manufactured plastic components. This chain is intended to extend from design through manufacturing preparation and production itself to downstream processes. This will not only shorten the product development process, but in the future, laser sintering will also enable the on-demand production of spare parts and component variants for mass-production vehicles. This will benefit not only the automotive industry.

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