Lehvoss and Evonik break new ground in industrial 3D printing

PA613 carbon fibre material Lehvoss and Evonik break new ground in industrial 3D printing

2023-11-06 Source: Lehvoss 2 min Reading Time

In collaboration, Lehvoss and Evonik have developed a new 3D printing material, PA613 with carbon fibre reinforcement, for industrial applications. This innovative material, developed specifically for laser sintering, combines low moisture absorption, high temperature stability and high process stability.

Laser-sintered components made from Luvosint PA613 9711 CF(Source: Lehvoss) — Laser-sintered components made from Luvosint PA613 9711 CF
(Source: Lehvoss)

Industrial 3D printing requires plastic materials that can be printed to the same level of performance as injection moulded parts. This is the key to being able to find applications for special components or in the aftermarket without major qualification efforts and design adjustments. The standard materials used in the plastics industry are mainly PP GF10, PP GF30 or PA6 GF30 — i.e. fibre reinforced materials.

Powder bed processes such as laser sintering offer almost unlimited geometric freedom when printing components. This is necessary because the parts originally designed for injection moulding have complex geometries. Unfortunately, reinforced polymers in powder form are a contradiction in terms. You can get away with dry fibres mixed into plastic powders. However, unbound, very thin fibres or microscopic mineral needles are risky to handle from an occupational safety perspective and are therefore not approved internally by industrial 3D printing processors. It doesn't help, the fibres have to get into the particles!

In collaboration with Evonik, Lehvoss has now developed a PA613 with compounded carbon fibre reinforcement. The base polymer PA613 was developed by the speciality chemicals company specifically for laser sintering. It is characterised by low moisture absorption, high temperature stability and — unlike PA6 — high process stability in laser sintering. The fibre reinforcement consists of high-strength XCF fibres, which have already been used in Luvocom XCF products for injection moulding. New approaches in particle technology have been taken in the production of the powder in order to preserve the fibre lengths in the individual particles as far as possible.

The printing of Luvosint PA613 9711 CF requires a build chamber temperature of 195°C, making it suitable for processing on standard laser-sintering machines. The material absorbs the wavelengths of CO₂, diode or fibre lasers.

“The fact that the first automotive OEMs have already qualified for spare parts production shows that we are on the right track. Nevertheless, in laser sintering, there still needs to be a lot of willingness to innovate in order to develop even more industrially relevant materials — including machines optimised for this — in order to bring industrial 3D printing into series,” says Dr. Marcus Rechberger, product manager for Luvosint at the Lehvoss Group.

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