Prototyping - 3D print / Additive Manufacturing

 

Series parts from from low volume quantity 1

We manufacture your components additively in almost injection molded quality. The material quality and process reliability of additive manufacturing technologies such as the HP Multi Jet Fusion (MJF) has progressed so far that even small to medium-sized series of end parts or spare parts can be manufactured.

Already during the development or when small quantities are needed, you have the possibility to order near-series models quickly and efficiently using the generative manufacturing process (MJF + FDM + DLP).

  • Online request / order:

CH: sauter@sautercar.ch / D: sauterstg@sautercar.de

 

Prototype parts in production grade thermoplastics

Our professional and powerful 3D printer systems cost-effectively create complex additive-fabricated components in plastic directly from 3D CAD or 3D scan data.

HP Multi Jet Fusion (MJF), Fused Deposition Modeling (FDM) and Digital Light Processing (DLP) technologies offer a wide range of engineering grade thermoplastics and resins – ideal for small batch production, prototyping, toolmaking and die making Production aids (very high functionality).

The 3D production systems HP MJF (PA12 sintering plant), Stratasys FORTUS 900MC, FORTUS 360MC, F370, uPrint (FDM) and 3D Systems Figure4 (DLP) systems can easily provide first parts for sampling and functional testing up to additive manufacturing of small series and series components for end products. Our Stratasys 3D Printers process a variety of high-quality thermoplastic plastics in manufacturing quality. The list ranges from ABS, CF Carbon, ASA to PC, PC-ABS, PP, up to PA12. Our high-performance FDM thermoplastic ULTEM™ 9085 is heat resistant up to 153 °C, permanently chemically resistant, flame retardant, low-smoke and does not develop toxic vapours. ULTEM™ 9085 meets the requirements of FST safety standards and is therefore ideally suited for use in the aerospace, rail vehicle, automotive and defence industries.

 

HP Multi Jet Fusion (MJF)

Such as Selective Laser Sintering (SLS) is a technology where the components are manufactured using a powder-based process with a layer height of 0.080mm. Instead of a laser, the HP 3D printer uses a multi-agent process for 3D printed parts in high detail resolution, quality, strength and durability.

A disadvantage is the heat distortion on the components, since the parts are processed in the powder bed and preheated the powder and the fusion by means of agent and heat lamp at about 180 ° C. Therefore, a high level of heat prevails in the powder bed and in the wrapped parts, which can lead to distortion of the parts.

The parts have a good bond between the layers (isotropic strength distribution and a homogeneous structure similar to an injection-molded part), are biocompatible, have high impact resistance and are resistant to most chemicals. The good heat resistance 175 ° C

 

Fused Deposition Modeling (FDM)

The component is produced by layer-wise application of the molten plastic wire (various original materials), which is applied by an extruder. These components, in turn, are stable, virtually distortion-free, permanently solid without shrinking, and absorb only low levels of humidity and remain dimensionally stable under changing environmental conditions. The finished components are left raw with fine coating lines or, if desired, finished (painted).

The disadvantage is a lower detail resolution resulting from the extrusion of the plastic layers (layer thicknesses 0.330, 0.254, 0.178, 0.127mm). For smooth visible parts, the method is therefore less well suited. The strength of the parts is less Z direction and therefore the parts are aligned to the direction of force.

 

Digital Light Processing (DLP)
In the DLP 3D printing process, UV-sensitive resin (photopolymer) is used as the starting material, with the difference to the UV laser stereolithography (SLA / STL) process curing a light-emitting source. Here, a projector serves as a light source. Layer by layer, the light cures the material at the desired location. Undercuts and superstructures are supported by a support structure built from the same material and then removed manually. A curing station hardens the parts.
These manufactured components have a very high level of detail and a beautiful surface. The main disadvantage is the limited usability of unpainted parts. Bedause the material as a photopolymer continuously absorbs UV light, the components are not permanently UV stable. In the case of master models, this does not matter, since there is no need for long storage.

You are looking for a development partner?

Do not hesitate to contact us.