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United States-One of the key components of plastic 3D printers is the extrusion head. In order to protect these components, a tip shield made of heat-resistant material must be processed. Savillex has developed a method to produce cutting-edge protective covers made of PFA through injection molding, allowing Stratasys and its customers to significantly reduce costs.
Stratasys is located in the Eden Prairie in the United States and is a leader in the development of 3D printers for rapid prototyping and 3D production systems for direct digital manufacturing. Innovative equipment manufactured by Stratasys enables engineers and technicians to develop new products and concepts in a fraction of the time experienced before. Stratasys' 3D production system provides manufacturers with solutions for production tools, fixtures, fixtures and even production parts.
The extrusion head is the key component that guides the molten plastic onto the part being built during the printing process. In order to protect this somewhat fragile component, a Tip Shield is installed on it. The Tip Shield must be made of heat-resistant material and has a release characteristic that allows the plastic to be completely detached from its surface. Stratasys engineers initially chose PTFE as the Tip Shield material. However, since PTFE cannot be molded into the exact shape required, these parts are produced through CNC machining operations. Since the tip guards are regularly replaced due to wear and damage, a more cost-effective solution is ultimately sought. Stratasys engineers contacted Savillex, hoping to find an injection molding solution.
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Savillex engineers used Stratasys to review the Tip Shields requirements and concluded that molded PFA parts might be a viable option. Subsequent testing by Stratasys confirmed that PFA is actually a suitable material for this application. However, the current design is not suitable for PFA injection molded parts. The wall part must be thickened and rounded. Savillex engineers worked with Stratasys to optimize the PFA molding design.
After the design is completed, multiple treatment options will be analyzed to meet the target cost. The tool designer at Savillex decided that a separate four-cavity tool was needed. Another consideration in tool design is that one of the part features critical to function has a very tight tolerance of +/- 0.001 inches. Because the shrinkage factor of PFA is very high, it is not easy to predict such molding tolerances. This aspect of the tool remains "tool safe" until the molded part can be analyzed. Then adjust the tool and lock the molding process. The result of the whole process is that Savillex uses its expertise in PFA molding to provide Stratasys with a large number of fully functional Tip Shields to meet its cost reduction goals.
The latest 3D printing solutions for tool and mold manufacturers
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