FAQs - Frequently asked questions about 3D printing at igus

3D printing refers to manufacturing digitally defined objects by means of layered application and bonding of material. The term "3D printing" is often used colloquially as a synonym for additive manufacturing. Additive manufacturing methods contrast with subtractive ones, such as machining, in which material is removed.

The best-known 3D printing processes are fused deposition modelling (FDM), selective laser sintering (SLS), selective laser melting (SLM), stereolithography (SLA), digital light processing (DLP) and multi-jet modelling/polyjet modelling.

In the igus® 3D printing service materials are processed using the SLS, FDM and DLP processes.

The production of an object using a 3D printing process requires at least three steps:

1. The object is created digitally in a CAD file and converted into a format that can be read by the 3D printer (e.g. STL)
2. The object is printed layer by layer
3. The finished object is cleaned and, if necessary, reworked (smoothing, painting, colouring, etc.)
   

The exact production technology depends on the printing method. There are many methods that are primarily distinguished by whether the material is added in the form of powder, molten plastics, or fluid and whether they are cured by light, air, or bonding agent. Depending on application, plastics, metals, ceramics, concrete, food or even organic materials can be processed with additive technologies.

3D printing is the manufacturing process of choice for complex-geometry parts, small batches and prototype development, since the fixed costs are much less than traditional manufacturing processes.

Depending on component geometry, however, 3D printing can also be the cheapest process in large-series applications. Die casting or injection moulding requires a mould that can be used only to produce a specific part. Before the next part can be produced, the mould must be replaced and the machine refitted. These costs must first be calculated based on the number of parts produced.

3D printed objects can also be produced in a very short time. For example, a 3D printed spare part can significantly reduce or even eliminate the costs of machine failure due to a defective part, since it is available more quickly and is often cheaper to produce.

Industrial 3D printing is used for manufacturing prototypes, tools, and series parts. It uses materials that, depending on the industrial application in question, must meet special mechanical requirements such as flexibility, rigidity and wear resistance.

The use of 3D printing in industry has proven to be particularly cost-effective, as models and small series can be created, tested and customised very quickly before a part goes into series production, in contrast to conventional methods.

Unlike prototypes that map only the geometries of the planned component, industrially manufactured 3D printed models allow all mechanical properties to be tested on the machine.

3D printing services are frequently used for industrial prototype manufacture, since procuring an industrial 3D printer is not cost-effective unless the company in question possesses the necessary expertise and uses the printer regularly to manufacture models and series.

3D printing service providers usually have not only the necessary expertise, but also several 3D printers, allowing them to select the method best suited to the application in question.

Depending on method, it is also much more cost-effective to engage an external service provider because such methods as laser sintering involve the regular manufacture of large batches of parts for various customers, greatly lowering production costs for individual parts and thus for individual customers.

The vibratory finishing minimally removes particles from the surface and can, for example, anticipate the shrinkage of a plain bearing point. It is a cost-effective and quick form of after-treatment, but is ineffective in places that the sliding bodies do not reach (e.g. inner edges, channels). The process is only suitable for smaller components with simple geometries.

The chemical smoothing process dissolves the plastic on the surface of the component. After the solvent has evaporated, a dense surface remains, while the untreated component always has a certain porosity, which plays a role in the use of lubricants, adhesives, compressed air as well as vacuum. This surface finishing produces even smoother surfaces than vibratory finishing, but also means a higher surcharge and a longer delivery time of the component (9-12 working days).

Both surface treatments can be carried out directly online in the iglidur® Designer can be configured and ordered in the "Finishing" tab.

Post-processing steps such as mechanical post-processing (drilling, turning, milling) and the insertion of threaded inserts are also possible for components made using the FDM process.

Please contact us about the Contact form if you need support for your application in this regard.

This is possible for some tribofilaments and has already been tested experimentally. For an assessment of your individual application, please contact us via the Contact form.

In addition to tribofilaments, a range of other filaments are also available for the multi-material 3D printing service, such as a flexible material (TPU) or high-strength materials reinforced with carbon fibre.

If you are interested, please contact us via the Contact form more.

Fastening threads can be printed directly from M6 or comparable dimensions. For this, the geometrical shape must be integrated in the 3D model. Alternatively, threads can also be cut or, in the case of heavily stressed or frequently screwed threads, threaded inserts can be used.

Please send a separate Offer Request.

igus® can provide components with threaded holes for trapezoidal or dryspin® threaded spindles upon request. lead screw nut for trapezoidal thread can be combined with the igus® CAD configurators generate. For dryspin® threads, please contact us via the Contact formas this is a protected geometry.

Thanks to the integrated solid lubrication, printed igus® components also work in a vacuum. Depending on the application, the maximum permitted gas release on the plastic component must be reduced to a minimum. Due to the higher density, the laser sintering process is recommended here rather than the FDM process. The gas release of laser sintering plastic components can be reduced by first drying and then infiltrating the parts. Both can be offered by igus and carried out directly during production.

So far, igus has been able to gain experience with components produced using the laser sintering process. It is known that untreated components do not have a high gas tightness. Gas tightness can be significantly improved by an infiltration process or by chemical smoothing, which has already been confirmed by customer feedback.

However, the gas-tightness always depends on the wall thickness; the thicker the wall, the more gas-tight the component. For components produced using filament 3D printing, a lower gas tightness can be assumed, which is why the SLS process is recommended here.

No, it does not. The solid lubricants are not affected by the heat. The same is true for injection moulding and bar stock materials, which also experience intense heat briefly during the manufacturing process without losing their self-lubricating properties.

The data basis for the service life calculator from igus® are the results of the 11,000 wear tests that igus® carries out annually in its in-house 300 m² large Test laboratory is carried out.

If a 3D model exists and there are no legal claims from the original manufacturer, this is possible. For commercial customers, igus offers to rebuild defective components.

Private customers have the opportunity to have the component redesigned and manufactured via local initiatives for 3D repair.

For simple parts such as plain bearings and gears, the igus® CAD configurators can be used.

igus® uses the EOS Formiga P110. Fundamentally, laser sintering 3D printers with CO2 lasers should be able to process iglidur i3 and iglidur i6 if the printing parameters can be adjusted. Positive feedback has already been received from customers with EOS Formiga P100 as well as 3D systems equipment.

Due to the different absorption of the laser energy, it is not suitable for low-cost systems such as Sinterit Lisa or Formlabs Fuse 1. Due to its black colour, the iglidur i8-ESD suitable, there has already been positive feedback from customers.

All iglidur laser sintering materials are fundamentally suitable, but the most suitable material for specific requirements can be selected. iglidur® i3 is the most frequently selected and most favourable SLS material in the igus range.® 3D printing service.

The best-selling laser sintering powder iglidur i3 is beige/yellow. We also offer powder in white (iglidur i6), black (iglidur i8-ESD) and anthracite (iglidur i9-ESD). For other colours, subsequent colouring of the printed components in the 3D printing service possible. 

The roughness of sintered materials is quite high, but it smooths quickly with use and does not affect the performance of the printed part.

Filaments from igus® are available in diameters of 1.75 mm and 2.85 mm. Some 3D printers require 3mm diameter filament. In practice, this refers to the diameter 2.85mm, so it should be used synonymously.

Therefore, the igus "3mm filament" can be used on printers that require 2.85mm or 3mm filament. Only the high-temperature filaments (iglidur RW370, A350 etc.) are currently only available in 1.75mm.

The dimensions of the filament spools can be found on the product pages in the Shop can be viewed here.

In most cases, yes, as long as the 3D printer allows the processing of third-party materials. If the printing parameters (speeds, temperatures, etc.) can be set yourself, there is nothing to be said against it.

The processing instructions can be found in the download area on the product page of the respective material in the Shop.

No, because these manufacturers, like some others, only allow the use of their own filaments.

For processing on the Bambu Lab X1C and Prusa MK3/MK4 and XL 3D printers, we offer printing profiles for the tribofilaments iglidur® i150, i151, i190. The pressure profile for iglidur® i180 is also available for the Bambu Lab X1C.

In addition, profiles for iglidur® i180, i150 and i190 are also available for some Ultimaker 3D printers (Ultimaker S3, S5, S7 and Factor 4). You will find an overview of all available print profiles and the respective processing instructions here.

The profiles for iglidur® i150, i180 and i190 can be selected in Cura via the Marketplace be installed. The software must then be restarted. The profiles only work for Ultimaker 3D printers (S3, S5, S7, Fact), and the materials can only be selected if such a device is set up in Cura. No profiles for other 3D printers are available for download in Cura.

Due to the large number of systems available on the market, it is not possible to make a clear recommendation. Basically, the printer should have a sufficiently large and closed build chamber as well as a heated print bed. In addition, a print head with two nozzles or two independent print heads that can heat up to 300°C, are recommended.

The device should also be freely configurable, i.e. the processing parameters should be adjustable and the processing of filaments from third-party manufacturers should be possible. Other useful specifications include interchangeable magnetic plates, network connectivity, direct drive extruder and automatic print bed levelling.

You should be able to process our filaments on most common printers without any problems. We will also be happy to send you material samples if you have purchased a printer. please contact us.

igus® offers the tribofilaments with the Bonding agent for tribo-filaments and the Adhesive films which can be ordered in the shop.

The adhesion promoter is applied as a liquid to a printing surface (such as glass) and serves as an adhesion medium as well as a release aid when the plate has cooled down.

The film is glued onto the printing plate and provides improved adhesion. The adhesion promoter is the only one suitable for Ultimaker 3D printers.

Drying filaments is generally recommended from time to time to ensure high surface quality and optimum mechanical properties and material printability.

Some filaments should be dried more frequently, e.g. iglidur i190, iglidur A350 and iglidur RW370. The filament spools can be dried in a standard household convection oven or in a dry air oven designed specifically for this purpose.

Further processing instructions can be found in the download area on the product page of the respective material in the Shop.

The rule of thumb is a drying temperature that does not exceed the maximum application temperature of the plastic, but also does not damage the plastic coil.

For filaments on matte black plastic spools max. 70°C, on transparent spools max. 90°C and on glossy black spools (high-temperature filaments) max. 125°C with a minimum drying time of 4-6 hours.

Further processing instructions can be found in the download area on the product page of the respective material in the Shop.

Depending on the tribofilament, various soluble filaments, including water-soluble ones, such as PVA, from various third-party suppliers can be used. For filaments such as iglidur i180, i190 and J260 with a higher processing temperature, a suitable support material for higher temperatures should be used if necessary (e.g. Formfutura Helios). An alternative is the so-called "Breakaway" support materials that can be easily removed by hand after 3D printing. For some tribofilaments, e.g. iglidur i150, PLA is also suitable as a support material, which can be removed manually without much effort after printing. We can make no recommendation for the high-temperature tribofilaments (iglidur RW370, A350, etc.) at the moment. Further processing instructions can be found in the download area on the product page of the respective material in the Shop.​

igumid P150 and igumid P190 are filament materials reinforced with carbon fibre, which have a much higher stiffness and strength than tribofilaments.

Some filaments can form a material compound due to their molecular composition. Many others cannot be easily combined with each other, so that a form-fit connection should be constructed here. Further information can be found in our Blog post on multi-material printing.

Appropriate mechanical reworking is possible. For machining on the lathe, the usual measures for unfilled plastics (e.g. POM), here it may be necessary to a holder must be produced to prevent deformation of the component during clamping.

Due to the increased wear resistance of the iglidur materials, grinding is more demanding than with standard plastics.

Yes, igus® has developed a tribologically optimised 3D printing resin for processing on DLP and LCD printers. It is particularly well suited to manufacturing very small components with fine details and smooth surfaces.

We 3D printing service wear-resistant parts can be ordered from this resin. The material is also available in the igus® Online shop are available.

It is possible that the production of such parts via igus® is more expensive than with other service providers, as materials specially optimised for minimum friction and wear are used.

There are iglidur i8-ESD because of its colour and antistatic specification, and igumid P150 or P190 because of its fibre reinforcement.

Yes and no. Modified plastics have a very high resistance compared to metals.

iglidur® i8-ESD is characterised by a specific resistance of 10⁴ - 10⁷ Ω x cm in the "antistatic dissipative" range, but not really conductive.

iglidur® i9-ESD has a higher resistance of 10⁶ - 10⁹ Ω x cm a medium conductivity. You can find more information about the two products in the Shop.

The tribofilaments iglidur® RW370 and A350 are fire-retardant according to UL94-V0. iglidur RW370 also complies with the EN45545 standard for railway vehicles.

The SLS material iglidur® i3 fulfils the FMV SS 302 or DIN 75200 for vehicle interiors. The certificates can be downloaded from the "Downloads" tab on the product pages in the Shop can be downloaded.

The SLS material iglidur® i6 and iglidur® i10 as well as the tribofilaments iglidur® i151 and A350 are approved for food contact according to FDA and EU 10/2011. The certificates can be downloaded from the "Downloads" tab on the product pages in the Shop can be downloaded.

Tests with iglidur® materials in rotation and swivelling applications under water have shown that the SLS material iglidur® i8-ESD is particularly suitable for these environmental conditions, as the wear rate in this environment is very low.

In the weathering test (8 hours irradiation with UV-A as well as 4 hours of condensation at 50°C for a total of 2000h / ASTM G154 Cycle 4), the laser sintering material iglidur i8-ESD showed a change in flexural strength of only around -9% with long-term resistance to weathering effects such as UV radiation. The laser sintering material iglidur i3 shows a change in flexural strength of approx. -14% and can therefore also be classified as resistant to weathering effects.

The chemical resistance of the tribofilaments and SLS materials can be checked using the searchable lists in the "Technical data" tab on the product pages in the Material shop or in the 3D printing service online tool can be viewed in the materials under "More information".

iglidur i3 has the longest service life of all igus® 3D printing materials in tests with spur gears. For worm gearboxes, due to the sliding relative movement between the mating partners iglidur i6 more suitable.

The best results in the service life comparison of tribofilaments and some standard 3D printing filaments are achieved by iglidur i190 and igumid P150. A detailed report on this is not available, but is planned for the future.

To determine the tolerance, you must take the dimensions of your component into account. Parts up to 50mm have a tolerance of ± 0.1mm. Parts larger than 50mm have a tolerance of ± 0.2%. These values apply to non-reworked parts.

Metallic gears can withstand higher loads than plastic gears. If you have a metal gear that is reaching the limits of what a metal gear can do, you cannot replace it with a plastic gear. That would require a gear three or four times the current size.

But if the metallic gear is not at the limit of what metallic material can do, you can, of course, replace it with a polymer gear, and then you have a system that requires no external lubrication and for which you can receive any type of gear very quickly. With our Service life calculator you can check directly whether this is the case for your application.

Our calculation tool works only from 17 teeth. Less than 17 teeth would require undercut information for the calculation, and our calculator has no option for adding or using it. If you require a gear with fewer than 17 teeth, you can contact your igus®-Contact person turn.

We can print parts that have undergone tooth correction. This is not currently reflected in our configurator. If you need such gear and do not have the possibility to design it, please do not hesitate to contact us. contact.

The 5 Nm act on the entire gear and not on the teeth.

You can customise your gear with the help of our gear configurator create.

With the expansion of our gear configurator gears with 8 teeth or more can now also be configured.

iglidur® tribofilaments are more suitable for bearings and other wear-resistant parts. Gears made from our laser sintering powders, on the other hand, have a much longer service life than those made from our filaments.

Our minimum wall thickness is approx. 0.7 mm. If we need to, we can go as low as 0.5mm, but we normally recommend a minimum of 0.7mm.

Yes, you will find the results of the wear test here.

You can make both gears from plastic and use our service life calculator to work out up to what point it works very well with plastic. But there will be a certain point at which the application with plastic gears will no longer work because the load is too high.

At igus, we always print all parts solid, so they are 100% plastic and can be reworked. We produce solid components because they are used as gears, bearings or other functional components in machines and should therefore have the highest strength. Of course, you can also design lightweight components to reduce weight. At your request, we can also print the gear wheels in non-solid form.

Feel free to contact us.

Before and during printing, the food-grade material must be protected from dust. We therefore recommend an enclosed build chamber.

Basically, all parts that come into contact with the filament should be free of residues. This applies in particular to the extruder sprocket and the pressure nozzle. In addition, a clean print bed is imperative. The glass plate should be cleaned and the use of either no adhesive or a food grade adhesive is recommended.

The settings should be selected in the slicing software so that the surface of the object is as dense as possible. Among other things, this is achieved by lowering the printing speed and adapting the line width to the nozzle diameter. This allows unevenness in the component surface and reduces gaps in the cover layers.

It is not recommended to produce food grade components in multi-material printing together with other, non-food grade materials, as mixing of the materials cannot be completely ruled out. The support material should either be food grade or the same material should be used as support material.

Components printed with food-compatible iglidur materials have a food-safe surface, so no additional coating is necessary. This applies to the 3D printing materials, iglidur i150, iglidur i151  and iglidur A350.

No, you only achieve food conformity by combining it with a clean 3D printing process. It is important to use clean print nozzles, for example, for the 3D printing of food-safe components. In addition, either no adhesive (glue) or a food-grade adhesive should be used.

If there is prolonged contact between the plastic component and food, this increases the chance of migration of plastic particles. Therefore, it is important to check the food compliance declaration for the maximum permitted contact time. This can vary depending on whether you consider the FDA or the EU 10/2011 declaration. The ambient temperature of the application also plays a role here. The higher the temperatures, the shorter the contact should be.