Inspired by Formula 1, the "Formula Student Germany" design competition pits student teams against each other in open-wheel car races. One of the parts the Formula Student team from Weingarten, near Ravensburg, Germany, needed to construct its race cars was customised plastic pinions for use as chain tensioners in the chain drive. Unfortunately, special-size pinions have long delivery times, and classic production with milling is time-consuming. The igus 3D printing service quickly assisted, producing the plastic pinions in less than 72 hours.
Designers not only save time, because the online configurator makes it easy to construct a digital 3D model. Special parts are manufactured using the so-called SLS process (selective laser sintering). A coater spreads an extremely thin layer of plastic powder on a building platform. The printer then uses a laser to fuse the powder wherever the component is to be produced according to the 3D model. The platform is then lowered by the thickness of a layer and the process starts again. After a few hours the sprocket is fully printed. Thanks to the 3D printing, the usual turning and machining with the corresponding drawing department are eliminated," explains Richy Göser of the Weingarten Formula Student Team.
"Probably the production with the 3D printer is also more economical in small quantities."
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