Easy spare part procurement with igus®

What was needed: A drive shaft bearing support for a high-bay warehouse

Manufacturing process: Selective laser sintering

Requirements:  A quick, easy bearing replacement, high wear resistance and sliding ability. A simple spare part procurement, simplified options for modifying or adapting the geometry and material selection

Material: iglidur® I3

Industry: Bearing technology

Success from the collaboration: Faster and easier plain bearing replacement by dividing the bearing, an increased wear resistance, increased sliding ability, increased process reliability, fast spare part procurement
 
The application at a glance:
The drive shaft bearing support for a high-bay warehouse broke due to the high load. In order to avoid a production stoppage, a replacement part was needed promptly. At this point, the high speed and design freedom of igu® 3D printing were employed and
initial tests with prototypes made of iglidur® I3 SLS powder were started. The company redesigned the bearings and split them so that the entire drive shaft did not have to be dismantled when replacing them. After successful tests, the bearings were ordered using the online CNC service. The replacement plain bearings made of iglidur® high-performance polymers have better wear resistance and sliding capability than plain bearings made of conventional plastic. In addition, the division of the bearings means that parts can be replaced more quickly and the system repaired more easily.  
 

Stopping the moving rack for repair may cause production stoppage

Problem

A defective plain bearing in the moving rack had to be replaced. Machine failure meant that production could no longer be supplied sufficiently with materials. The drive shaft plain bearing needed to be replaced in the shortest possible time. However, the drive shaft was difficult to reach and the replacement proved to be very complicated, since the drive shaft had to be dismantled. The new plain bearings also needed to withstand harsh environmental conditions such as dust, dirt and material residue from the high-bay warehouses.
 

Solution

In order to simplify the installation situation, the bearing was redesigned. A split bearing was used. In the future, it will allow quick replacement without the necessity of dismantling the entire drive shaft. In addition to the design freedom of the components made possible by 3D printing, the company was also impressed by the iglidur® I3 material. This was specifically developed for laser sintering and features increased wear resistance and sliding ability. After the tests, the newly designed bearings were ordered from the online CNC service. For the company, igus® plain bearings meant increased process reliability, quick spare parts and a flexible option for modifying the parts if they needed to be reworked.
 

Simply redesign and order in three steps

To make replacing the drive shaft's plain bearings as efficient as possible, the company redesigned the component in CAD tool as a split bearing. This design was first tested with 3D printed bearings made of iglidur® I3. The additively manufactured components are usually ready for dispatch in one to three days and this works particularly well for initial test applications. In the igus® online 3D printing service, the individual component can be ordered in three steps. The service life can also be calculated with the application parameters given. There is also no minimum order quantity in the igus® 3D printing service and the service tool displays the unit price instantly.
 

Wear-resistant spare parts from igus®

In addition to the freedom of geometry in 3D printing, the high abrasion resistance of the igus materials is also great for wearing parts from a 3D printer. In the igus test laboratory, the different materials are tested in order to be able to make reliable statements about component service life. Among the items tested were the tribological properties of the iglidur plastics. Their abrasion resistance was 30 times that of conventional materials for laser sintering. Wherever wear is unavoidable, igus materials with their good mechanical properties and longer service life than that of conventional plastics provide an advantage. If you have any questions about the right material for customized applications, the 3D printing team is at your disposal. "The colleagues' response time was excellent," reads the WAREMA Sonnenschutztechnik GmbH feedback.
 

The newly designed plain bearing ensures easier replacement on the drive shaft