Ma­ter­i­al qual­i­fic­a­tion for Ar­burg Plastic Free­form­ing (AKF), Fused De­pos­ition Mod­el­ing (FDM) and Fused Gran­u­lar Fab­ric­a­tion (FGF)

On behalf of interested companies, Kunststofftechnik Paderborn carries out material qualifications for the processing of proprietary or new materials using the AKF and FDM processes. With regard to both technologies, we draw on many years of experience from our research activities in the field of processing innovative materials. In addition, we use specially developed procedures to first test the suitability of the new materials for processing and then optimize all relevant process parameters. The aim is to develop process parameter data sets that can be used to manufacture complex components from the new materials using the AKF, FDM or FGF processes.

Fil­a­ment pro­duc­tion for FDM

In addition to material qualification, Kunststofftechnik Paderborn also offers the production of filaments for further processing on FDM systems. This service can be ordered as part of material qualification for a new type of material in the form of plastic granulate or as a stand-alone service. High-quality plastic filaments are produced on the available, high-temperature-capable extrusion line. The extrusion line consists of a miniature twin-screw extruder Process 11 from ThermoFisher, an associated melt pump, a filament winder and a laser-based measuring system for monitoring and recording the filament diameter. The filament is supplied in the form of spools including documentation of the filament diameter.

Pro­duc­tion of pro­to­types in AKF, FDM and FGF

One of the largest areas of application for additive manufacturing continues to be the production of prototypes as part of product development. Kunststofftechnik Paderborn also offers comprehensive services in this area. With the AKF, FDM and FGF processes, plastic components can be produced with almost complete design freedom without the use of a shaping tool.

The AKF process in particular enables the direct production of prototypes from a desired plastic granulate. For example, prototypes can be additively manufactured from the original injection molding material for later series production and tested in extensive functional tests. Compared to the FDM process, the intermediate step of filament production is not necessary with the AKF process. At the same time, the components and prototypes produced using the AKF process have a very good surface quality, which makes them particularly suitable as demonstration samples. Another advantage of the AKF process is the processing of particularly soft materials.

The FDM process, on the other hand, impresses with the rapid provision of components or prototypes made from high-performance polymers, such as polyetherimide (PEI). Such materials are already qualified for the FDM process so that the production of components can begin directly on the basis of a CAD volume model. Kunststofftechnik Paderborn can also support you on request.

The FGF process is similar to FDM, but does not rely on filaments as a raw material and can be operated directly with standard granulate. The available machine (Queen 1, Q.Big 3D) has a particularly large installation space of 1 m x 1.70 m x 1 m, so that parts that would previously have had to be joined can also be produced in a single step.