3D Print Queen Large components become additively manufacturable with the VFGF process

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FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

With the so-called VFGF process (Variable Fused Granulate Fabrication) from Q.Big 3D, even oversized plastic parts can be 3D printed. Here is the proof ...

The additive manufacture of oversized plastic parts offers enormous advantages for the tool-free production of small and medium series, as it is said. The key to this is the Variable Fused Granulate Fabrication (VFGF) process from Q.Big 3D. Reiser Simulation and Training GmbH, based in Berg near Starnberg, commissioned a Full-Flight Simulator (FFS) for helicopters in this context. Murtfeldt Additive Solutions GmbH (Murtfeldt AS) from Kusterdingen was then tasked with the production of a modular cockpit, which was then printed on a Queen-1 system from Q.Big 3D at Murtfeldt. The tool-free production with a 3D extrusion printer allows for timely time-to-market strategies.

The advantages of the VFGF process for large components

The elimination of tool costs and new strategies of component geometry in construction meet extremely short amortization time of the plant technology. The special feature compared to other possibilities for additive manufacturing (such as FDM printers), is the use of commercially available standard plastic granulates. So, no plastic filaments are needed. The aim of the project for additive manufacturing of the Reiser helicopter cockpit at Murtfeldt AS was to overcome the previous limits of conventional manufacturing processes with a contemporary laser sintering strategy (SLS). Thus, high tooling costs are incurred in classic form-related processes, especially for large-volume components, associated with long lead times. Also, classic FDM printers (Fused Deposition Modeling) usually cannot manufacture too large components, as the build rates are uneconomical and the plastic as a filament can cost up to seven times more per kilogram than standard granulate. Therefore, a Queen 1 from Q.Big 3D was used, which is available at Murtfeldt AS for oversized SLS components. The execution of such a project is possible within 3 to 6 months according to the companies involved.

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This is how you build a modular helicopter cockpit

The 3D cockpit was manufactured with all elements of the assembly on a Queen 1 from Q.Big 3D at Murtfeldt AS. The dimensions of the cockpit are 2,260 × 1,780 × 1,705 millimeters. However, it weighs only 200 kilograms, because 3D printing allows resource-saving lightweight construction. The assembly of all components took little more than a month. For a follow-up project, Murtfeldt AS expects shorter set-up times through optimization of the process chain. Through a network of several Queen-1 machines, the delivery time for time-critical requests can also be shortened. The longest individual construction job took just under 100 hours, we learn. Bionics and functional integrations are also possible with this. From a know-how point of view, one must be able to master the problem of warping with large components. Tight tolerances of the gap dimensions and high surface qualities are added challenges. Above all, dimensional accuracy is important for screwing and pinning. The concept as a disassemblable module was just as advantageous for assembly by the user, as well as the fact that with a "conversion kit", two helicopter models (Airbus Helicopters H135 and H145) could be depicted inexpensively. Last but not least, functional integrations like integrated cable ducts are possible through segmentation of the 3D assembly. Also, the cockpit was quickly available.