Rapid Prototyping / eManufacturing

Rapid prototyping is the quick generation of 3D prototypes using generative (additive) composite sandwich structures, whereby 3D data are used to generate consistent layers which are joined together to form a component.

One of the advantages of this process is its speed, another is its design freedom, as the complexity of the components being generated hardly plays any role at all. Undercuts, sharp edges, free-form surfaces, hollow bodies or even components within one another can be produced quickly without any problems. Product development times can be dramatically reduced as early on as in the product development process thanks to this method.

eManufacturing is the next step. This method is used to generate end products, functional parts, replacement parts and tools. The increasing trend towards customised products produced in small production runs and an ever greater number of variants make this method very attractive.

Here at H&H, we use the two most common processes of stereo lithography (STL) and laser sintering (SLS). However, components can also be supplied from our reliable partners who use many other processes such as fused layer modelling (FLM/FDM) or layer laminated manufacturing (LLM/LOM).


Stereo lithography (STL)

The liquid resin is solidified in situ in layers using a UV laser (photopolymerisation).

Benefits: Extremely high level of component accuracy, high degree of detailing, good surface finish. The materials are therefore particularly suitable for producing casting moulds. Accura 60 is suited to well-defined components and ProtoTherm components are capable of withstanding temperatures of up to 150 °C.

Limits:
  • Minimum wall thickness 0.5 mm
  • Layer thicknesses from 0.05 to 0.15 mm
  • Large components are cut, assembled in several parts and then joined together
  • Single piece 250 x 250 x 250 mm
Area of application:
  • Master patterns for casting moulds
  • Design models
  • Functional models
  • Data control models
  • eManufacturing
Materials:
  • Accura Xtreme, Accura 60 ProtTherm 12110
Machines:
  • 3D Systems Viper,
    EOS Desktop 250

Selective laser sintering (SLS)

The pre-heated powder material is sintered locally in layers using a CO2 laser.

Benefits: Excellent mechanical properties and stability, making it very suitable for functional components; integral hinges and snap fasteners are also possible. Good surface quality and level of detail. Material properties remain close to that of the series material. Components can be used immediately and are easy to weld or glue.

Limits:
  • Minimum wall thickness 0.5 mm
  • Layer thicknesses from 0.08 to 0.3 mm
  • Large components are cut, assembled in several parts and then joined together
  • Installation space 381 x 350 x 457 mm
Area of application:
  • Functional models
  • Design models
  • Installation tests
  • Design test
  • Form and fit tests in the medical field, surgery
  • eManufacturing
Materials:
  • Polyamide 12 (Duraform)
  • Glass-/aluminium-filled polyamide
Machines:
  • DTM 2500plus, DTM 2000

Fused Layer Modeling (FLM/FDM)

The molten material is applied in layers using a heated nozzle.

Benefits: Good component accuracy; do not tend to warp. It is possible to produce multi-coloured models. Very suitable for thick-walled, bulky components.

Limits:
  • Minimum wall thickness 0.5 mm
  • Layer thicknesses from 0.125 to 0.330 mm
  • Large components are cut, assembled in several parts and then joined together
  • It is difficult to smooth the surface
Areas of application:
  • Functional models
  • Installation tests
  • Master patterns for precision casting
  • Master patterns for casting moulds
Materials:
  • ABS, PC, PC-ABS, some available in various colours
 

Metall Laser Sintering (DMLS/SLM)

The pre-heated powder material is fused on locally in layers
using a fibre laser.

Benefits: Tool-less fabrication, almost 100% dense metal components with a very high level of accuracy and homogeneous, constant material properties. It is possible to produce conformal cooling channels in tool inserts. High mechanical strength and a wide range of materials.

Limits:
  • Minimum wall thickness 180 μm
  • Layer thicknesses from 0.05 to 0.3 mm
  • Surface roughness less than 20 μm
  • Single piece 280 x 280 x 350 mm
Materials:
  • Titanium, tool and stainless steel, aluminium, cobalt-chromium, Inconel
Areas of application:
  • Tools
  • Tool inserts
  • Functional components
  • Turbines / power trains
  • Dental applications: bridges, crowns
  • Surgical instruments
  • Jewellery

3D printing (3DP/Objet)

The liquid resin is applied in layers by heated print heads and solidified by a UV lamp (photopolymerisation).

Benefits: Ultra-thin layer thicknesses of 0.016 mm; very smooth surface and a high level of detail. Can be used immediately as it has hardened completely. Possible to produce multi-coloured components.

Limits:
  • Minimum wall thickness 0.6 mm
  • Layer thicknesses from 0.016 to 0.03 mm
  • Resolution (xyz) 600 dpi x 600 dpi x 1600 dpi
Areas of application:
  • Functional components
  • Master patterns for casting moulds
  • 2K hard/soft components
  • Jewellery
  • Design components
Materialien:
  • FullCure720Transparent, VeroWhite, VeroBlack, VeroBlue, VeroGray, TangoBlack, TangoGray

3D printing (3DP/3D systems)

The liquid resin is applied in layers by heated print heads and solidified by a UV lamp (photopolymerisation).

Benefits: Layer thicknesses of 0.032 mm; very smooth surface and a high level of detail. Can be used immediately as it has hardened completely. Possible to produce multi-coloured components.

Limits:
  • Minimum wall thickness 0.6 mm
  • Layer thicknesses from 0.032 to 0.038 mm
  • Resolution (xyz) 656 dpi x 656 dpi x 800 dpi
Materialien:
  • VisiJet Flex, VisiJet Tough, VisiJet Clear, VisiJet HiTemp, VisiJet e-Stone, VisiJet Mx

 

Areas of application:
  • Functional components
  • Master patterns for casting moulds
  • Multi-coloured components
  • Jewellery
  • Dental wax-ups
  • Design components