Prototyping - 3D print / Additive Manufacturing

 

Series parts from from low volume quantity 1

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

Already during the development or if small quantities are required, you have the opportunity to have close-to-series models manufactured by us quickly and efficiently using additive manufacturing processes (SLS+ MJF+ FDM+ DLP and DLP+).

Prototype parts in production grade thermoplastics

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

With the processes: Selective Laser Sintering (SLS), HP Multi Jet Fusion (MJF), Fused Deposition Modeling (FDM) and Digital Light Processing (DLP and DLP+), there is a large selection of thermoplastics and resins in technical quality – ideal for the production of small series, prototyping, tool making and production aids (very high functionality).

The 3D production systems can easily provide the first parts for sampling and functional tests through to the additive manufacturing of small series and series components for end products. Our Stratasys 3D Printers process a variety of high-quality, manufacturing-grade thermoplastics. The list ranges from ABS, CF Carbon, ASA to PC, PC-ABS, PP and PA12. Our high performance FDM thermoplastic ULTEM™ 9085 is heat resistant up to 153°C, permanently chemically resistant, flame retardant, has low smoke and no toxic fumes. ULTEM™ 9085 meets the requirements of FST safety standards, making it ideal for use in the aerospace, rail vehicle, automotive and defense industries.

The thermoplastic elastomer TPU 92A and SLS TPE are available for complex elastic components. Washing systems (for FDM) or glass bead emitters (for SLS+ MJF) remove the support material or powder.

We are happy that we can create parts for you. You can contact us for inquiries/orders as follows:

instant request

(Upload 3D data directly)

E-Mail
CH: sauter@sautecar.ch
D: Info@sautercar.de

Call up
CH: +41 61 703 17 77
D: +49 7032 913 967

Selective Laser Sintering (SLS)

Selective laser sintering, also known as the SLS process, is a process for printing plastic parts using a laser. The component is created on the surface of a heated powder bed, which is why SLS is one of the powder bed processes. Unlike the FDM/ FFF or DLP process, no support structures need to be created to support the component. The surrounding powder in the printer provides sufficient support for the component. This enables a great deal of design freedom and allows functional components or prototypes to be assembled and manufactured directly. The materials used also have a high mechanical resilience. The parts show good bonding between the layers (isotropic strength distribution and a homogeneous structure similar to an injection molded part), have high impact strength and are resistant to most chemicals.

HP MJF – Sinter (PA12)

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 also named FFF)

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.

Material selection: SLS and HP MJF

PA11; PA12; TPE; (in validation: PP)

Material selection: FDM/ FFF

ASA; PC- ABS; ABS-CF10; DIRAN 410 MF07 (PA6); ABS-ESD7; TPU 92A BLACK; PC; Nylon6; Nylon12; ULTEM 9085; ULTEM 9085 CG; ULTEM 1010; ULTEM 1010 CG; Antero; Nylon12 CB; ABS- M30; ABS- M30i; PC-ISO; ST130

Material selection: DLP

PRO BLK 10; FLEX BLK 10; Hi Temp 150C FR; Tough 65C BLK; FLEX BLK 20; RUBBER 65 BLK; RUBBER BLK 10; MED WHT 10; MED AMB 10; Rigid WHITE; Rigid Grey; TOUGH GRY 15; TOUGH BLK 20; Touth 60C WHT; JCAST GRN 10; JEWEL MASTER GRY; EGGSHELL AMB 10; Tough Clear

Material selection: DLP+

Durable DL110H BLK; Durable; Duramax; Durable
DL110H WHT; Hard; High Tensile; High Temp DL400; Draft; Concept; Flexible DL220B BASF: EPD 1006; EPD 2006; EPD 1086; EPD 3500; EPD 4006

E-Mail
CH: sauter@sautecar.ch
D: Info@sautercar.de

Call up
CH: +41 61 703 17 77
D: +49 7032 913 967

You are looking for a development partner?

Do not hesitate to contact us.