Threaded nut from the 3D printer for actuator

Technical data:

What was needed: An alternative to metallic ball screw nuts that can be manufactured independently using 3D printing
Requirements: 100% lubrication and maintenance-free, quiet running, easy to manufacture, smooth running, clearance-free
Material used: 3D print filament iglidur® i190-PF
Success for the customer: There was no other way to achieve the set goal for the design. The parameters were predetermined and the end product had to work. Optimising the contact surface was crucial for reducing friction. The surface hardening of the threads also reduced friction. After several printing trials, the print quality was improved.

Threaded spindle on a machine bracket with mounting plate and bolt.

Problem

Volker Krebs from VKC Services Ltd in Canada needed a lead screw nut. Metal ball screw nuts are too heavy and also require regular maintenance and lubrication. In a 6DOF (6 directions of force) simulator, the noise of the ball screw can be very disturbing over time. The simulators are used indoors and therefore operate in a constant temperature environment. The biggest challenge was to find the right tolerances to achieve a smooth-running and clearance-free screw drive. The ball screw bearing converts rotation into linear motion. Use in an actuator requires that they can withstand linear acceleration forces of up to 3 g under various load conditions. The average motor speed is 800-1200 rpm, but can also be up to 3000 rpm. The load per drive is approximately 1500N.

Solution

Volker Krebs has designed a replacement for a ball screw nut. The material for this is the iglidur® i190. By using igus® linear bearings and now also iglidur® i190 3D-printed polymer-lead screw nut, the simulator becomes a truly mechanically quiet simulator. The inner slider of the actuator has also been integrated into the nut design to facilitate maintenance. In the design there was no other way to achieve the set goal. The parameters were set and the end product had to work. Optimising the contact surface was crucial to reducing friction. The surface hardening of the threads also reduced friction.

Further application images:

White igus part on a black digital scale showing 95.6.

3D-printed plastic part with internal thread on a table.

3D-printed threaded part with flange on a wooden table.

Threaded spindle on a machine frame with guide rods and a metal plate.

Three white plastic parts and three flange bearings on a desk.

Further 3D printing applications

Cleanroom 3D printer

What was needed? A precise and reliable cleanroom 3D printer for processing thermoplastics
Requirements: Absolutely lubrication and maintenance-free, long service life, suitable for clean rooms, no abrasion, cost-efficient
Success for the customer: Design freedom was gained on all linear guides by using the drylin®® -bearing with exchangeable sliding foils. This has significantly accelerated the design process. The sliding foils prevent unwanted particle release and at the same time offer process stability. There were other advantages from using suitable rail and shaft guides for system implementation.

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3D printer in a closed test cell with filament guide and part holder.

Portable 3D printer

What was needed? A 3D printer that is compact and portable, but can still produce detailed 3D parts
Requirements: Best performance even in tight installation spaces, no maintenance, 100 % lubrication-free, low wear and friction, smooth dry operation, vibration- and noise-free, no adhesion of dust and dirt
Success for the customer: In developing countries and emergency areas, a portable device with high precision is very helpful. It is a radical advance for dental and medical care. The igus® products in the 3D printer ensure a long service life, clean printing conditions, and dry operation without vibration or noise.

Go to application

Lumifold device with the lid raised and internal components visible.

3D printer that makes itself

What was needed? A 3D printer that can produce its own essential parts quickly and precisely
Requirements: High precision and working speed, no vibration, low weight, lubrication-free, low friction
Success for the customer: The xBot is aimed at private users as well as schools, universities and industry: "The printer is not only fast and precise, but also high-quality and durable. It can process a variety of materials - from compostable PLA to standard ABS to flexible materials such as nylon and rubber-like plastics. The construction is solid and all the main components are manufactured in AT or DE."

Go to application

The drylin R linear guide in a 3D printer guides the print head precisely.

Fabforge Innovations 3D printer

What was needed? A precise and quiet 3D printer that fulfils the requirements for "Made in India"
Requirements: 100 % lubrication and maintenance-free, precise, quiet and vibration-free running, smooth dry operation

Success for the customer: Fabforge Innovations is a manufacturer of 3D printers based in South India and operates nationwide. It used to use linear rails from other manufacturers, but to meet the "Make in India" conditions, Fabforge Innovations changed the design and used igus® products.

Go to application

CAD model of a linear setup with several igus guide elements and axes.

Mini 3D printer

What was needed? A compact and cost-effective mini 3D printer
Requirements: During printing, a tray must perform extremely precise vertical movements in order to achieve a high print resolution of 50 micrometres. In addition, the smallest possible components had to be found for the compact 3D printer.

Success for the customer: With the help of drylin® components, the Lumi Pocket is a 3D printer that combines an extremely compact design with outstanding print quality and an unbeatable price.

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LumiPocket application with 3D-printed samples and a transparent part.

3D printer office

What was needed? A large-format and precise 3D printer that is suitable for use in offices or workshops
Requirements: Maintenance-free, easy installation, high accuracy, 100 % lubrication-free, no dust and dirt adhesion, quiet and vibration-free due to office use
Success for the customer: The engineers use linear guides, slides, threaded spindles and lead screw nuts of the type dryspin® for the linear movements of all three axes. The lead screws allow travel speeds of up to 120mm/s. All components help to minimise maintenance of the 3D printer. The right 3D printer in the office.

Go to application

Linear axis with carriage and guide on a grey background.

Do you have questions about drylin® lead screw technology?
Our expert Thorben Hendricks will answer all your questions about drylin® lead screw technology. Simply fill in the contact form and we will take care of your enquiry. We look forward to hearing from you!

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