Explore a new range of high strength applications
The Ultimaker Metal Expansion Kit makes creating metal parts and tools easier, more efficient and more affordable.
And that's exactly what a group of industry leaders has done.
Scroll down to see what's possible with metal 3D printing (MFFF) , read Ultimaker customer application stories and get inspired by what you can create and the savings you can achieve.
Sparox 3D Solar Panel Bracket
Wien Energy delivery to save thousands of euros
Sparox 3D is a business-to-business platform that, since 2018, has been producing spare parts and custom products for Wien Energy and parent company Wiener Stadtwerk, as well as external customers.
The organization primarily serves clients in the energy sector, as well as transportation, oil and gas – all industries that depend on legacy systems and need to keep those systems running for as long as possible. When parts break, it is important to replace them quickly and it is desirable to optimize against future failure if possible.
Sparox recently switched from exclusively manufacturing polymer parts for its Ultimaker 3D printers to manufacturing eco-friendly metal parts. Working with BASF Forward AM materials and greenprint disassembly and sintering service provider Elnik GmbH, Sparox can now obtain solid metal parts quickly and affordably, while maintaining better control over their design. The end-use items produced in this way are already in use at Wien Energy as well as external customers.
A challenge
Sparox had difficulty finding the bracket needed to attach photovoltaic (PV) solar panels. The bracket was discontinued for maintenance by the stock manufacturer and the guide rail assembly was obsolete.
Answer
Replacement brackets are designed and printed using MFFF technology. Metal stamping was chosen because the part needed to be durable and weatherproof to survive outdoor conditions.
Results
The resulting stainless steel part was both weatherproof and more durable than the previous aluminum part. The cost savings of printing the part instead of overhauling the existing rail assembly was several thousand euros.
Welding fixture from Hoedtke 3D Additive
Extending the life of their machine fixtures with metal FFF parts
Based in Pinneberg and Kiel, Germany, Hoedtke is a supplier that specializes as an engineering office and manufacturing company in the processing of metal materials. They have been in business for over 75 years.
The technologies offered by Hoedtke are used to manufacture parts, prototypes, assemblies and systems for a variety of industries, including the automotive, computer and electrical industries, research institutes, aircraft and mechanical engineering, medical technology and more.
A challenge
The injection-molded fixtures used in Hoedtke welding machines suffered from a short life. These parts cracked and deformed due to the high mechanical loads and high temperatures to which they were regularly subjected.
Answer
The decision was made to replace these injection molded components with metal parts printed on an Ultimaker printer. The metal material would be more durable and heat resistant than the existing polymer based material that the bodies are made of.
Results
The new metal 3D printed bodies had significantly longer lifespans. Because the part can be designed to exact specifications, there is no need to make modifications to the welding machines themselves. Such changes would be much more expensive. But with this MFFF technology, the fixture can be easily replaced.
Metal 3D printing has become affordable
Hoedtke is one of many companies realizing the difference metal 3D printing can make in their manufacturing.
Blade fan assembly from Schwartz Off Road Motorsportz
Using MFFF for custom parts
Owner and driver, Erik Schwartz is an engineer by trade and spends all his free time tinkering and maintaining his vehicle to compete in the Championship Off Road Series. Skillfully turning his ideas into reality to make improvements, Schwartz uses Ultimaker 3D printing technology.
Once considered a novelty, 3D printing has become a necessary tool for this team to compete at a high level. With advanced material options available with the Ultimaker S5, Schwartz Off Road Motorsportz (SORM) saves time on and off the track.
A challenge
Every year, Schwartz Off Road Motorsportz builds a new one-of-a-kind SxS Pro Mod race car from scratch. In their latest car they use a custom mount to attach an electric fan to the radiator.
While the part was previously 3D printed using a carbon fiber nylon material, the temperatures in the engine bay were at the upper end of what this material could withstand.
Answer
A new assembly was printed using BASF Forward AM Ultrafuse® 17-4PH. This metal material not only met the temperature requirements, but also provided the necessary strength to be tight, allowing it to withstand the demands of competition.
The new mounting design features a custom profile that perfectly matches the OEM mounting points on the fan housing, allowing it to slide snugly into the fan. The other side of the mount uses a slot that allows the mounted mount to be adjusted to match the custom bores that Schwartz Off Road Motorsportz designed into their engine.
| Time to print | Weight | price |
|---|---|---|
| 4 hours 30 minutes | 154 gr. | $22.92 |
Results
The new part is not only more reliable due to improved temperature resistance, but it is also customizable. Which means it can be adjusted more easily to meet the requirements of the one-of-a-kind vehicle designed by Schwartz Off Road Motorsportz.
From plastic to metal 3D printing
Schwartz Racing is one of the many companies that realize the difference metal 3D printing can make in their production.
Interested in 3D metal printing?
If you have been inspired by the stories shared and think that you can implement metal 3D printing in your business as well, do not hesitate to contact us to help you do it faster and easier! We are waiting for you at our address: Yambol, 14 Georges Papazov St., office 407 or contact us by phone 0885636868.
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