Formnext 2024 Additive manufacturing for large-volume 3D plastic components

Related Vendors

Q.big 3D GmbH

HASCO Hasenclever GmbH + Co KG

AMPCO METAL Deutschland GbmH

Renishaw plc

Q-Big 3D’s innovative VFGF (Variable Fused Granulate Fabrication) process unlocks new possibilities in large-scale 3D printing, making the production of massive components both economical and efficient. Utilizing commercially available plastic granulate and a variable nozzle that adapts between turbo and detail modes, VFGF enables rapid production without the high costs and lead times.

Big. Bigger. Really Large. 3D extrusion printing unlocks the potential of making large-volume components economically viable. One key to this is the VFGF (Variable Fused Granulate Fabrication) process from Q-Big 3D. Rapid availability of components, very short amortization periods and high cost-saving potential are among the characteristics of this manufacturing strategy. And there is a cost-relevant advantage compared to alternative 3D printing approaches: the use of commercially available plastic granulate instead of high-priced polymers with filaments. The key element, however, lies in a special feature of the process: the use of a variable nozzle (variable fusing process), which can vary between a turbo and a detailed build mode during the creation of the component.

Previous limitations of conventional manufacturing strategies can be overcome with VFGF system technology. Classic mold-based processes, for example, especially for large-volume components, involve high tool costs and long lead times. In addition, classic FDM printers (Fused Deposition Modeling) are usually unable to produce large-volume 3D components. Build rates are uneconomical and the price per kg of the filament material is often significantly higher than that of granulate.

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A central element of the VFGF process is the use of a variable nozzle to extrude the material. VF stands for Variable Fused in addition to GF, which stands for Granulate Fabrication, i.e. 3D extrusion printing. What is so special about a variable nozzle? The variable nozzle can print quickly with high material throughputs in a so-called turbo mode, used for example in the case of in-fill areas inside the geometric form. In other areas of the component high precision is ensured with low material throughputs in the detail build mode. The variable nozzle of a Queen1 system by Q-Big 3D works with a combination of 1.5 mm (detail mode) and 3 mm (turbo mode) and applies the material layer by layer, like a typical 3D printer. This makes it possible to produce very large-volume components economically without the use of molds. This offers high resolution printing with a short production time — along with low material costs. The maximum processing speed is 500 mm/s. The system enables a dynamic output of 0.15 – 2.0 kg/h. The variable nozzle works in detail mode for fine structures or textures. This can be a surface that needs to be accurate for high-gloss painting, but also for holding fastening elements. Inclined areas or overhangs with the necessary support structures can also be component requirements. Bridges or thin domes are also possible. The turbo mode, on the other hand, enables rapid build times, needed for very large components, with regard to the cost-effectiveness of an additive manufacturing strategy in order to be able to compete with conventional processes such as injection molding using granulate material. The turbo mode is selected for in-fill areas or for creating support struts on the back of components in non-visible areas. During the build, printing commands sent to the Queen1 system are defined in areas of the component for detail or turbo printing and validated by simulations. For the design engineer, this also opens up the possibilities of bionic strategies or material savings in the context of lightweight construction.

An example of large-format 3D printing is the 3D cockpit for a helicopter simulator, additively manufactured on a Queen1 system from Q-Big 3D at Murtfeldt Additive Solution. Cockpit dimensions measure 2,260 mm (x), 1,780 mm (y) and 1,705 mm (z). A low weight of only 200 kg was realized by 3D printing with turbo and detail build modes using the variable nozzle which enables resource-saving lightweight construction.

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