ARBURG at rapid+tct 2024

freeformer 750-3X machines can process original plastic granules, including certified materials, using ARBURG Plastic Freeforming (AKF), including in hard/soft combinations and from high-temperature materials. To achieve this, the temperature of the build chamber can be raised to 200 degrees Celsius; the plastification takes place at up to 450 degrees Celsius. A typical application is the production of geometrically sophisticated ventilation ducts for the aerospace industry from original Ultem 9085 granules. The 750 square centimetre part carrier can be used to produce larger functional components or additively manufacture small batches on an industrial scale.

The GESTICA control system is optimised for additive manufacturing in terms of process stability, component quality and build time. Based on the slicing data, the system calculates exactly how much material is required to build each individual layer. Variable dosing behaviour helps to reduce the residence time. Customised orthopaedic insoles up to shoe size 50 will be used as an example to show how the build time and costs per component can be significantly reduced thanks to optimised software features and grid-shaped support structures, among other things. Depending on the needs of the wearer, the insole can be individually reinforced or specifically designed to be soft – either through a multi-material combination, e.g. of hard PP and flexible TPE, or by adjusting the filling density. Thanks to an adapted discharge strategy and layer thickness, the build time here has been reduced by 72 per cent.

The use of additively manufactured functional components in safety-relevant areas is an essential requirement for a reproducible and reliable additive manufacturing process. For patient-specific implants and ventilation ducts in aeroplanes, for example, it is imperative that the production parameters for each individual component can be fully documented and traced. To do this, ARBURG offers its customisable "ProcessLog" customer portal app, which displays and documents a wide range of process and build job data in a clear graphical format. This significantly reduces rejects and error rates. The data can be scaled and displayed in a clear graphical format.