Gears are the heart of many mechanical systems. They drive machines, enable precise movements in robots, and are indispensable in gearboxes and automata. Customized and durable gears are increasingly in demand. Therefore, igus has now developed a new 3D printing resin for the DLP process with iglidur i4000. This innovative material is specifically designed for the unique requirements of gears, has a 13 times higher elongation at break, and offers up to 5 times longer service life than conventional 3D printing resins.
Three years ago, the plastic specialist igus launched its first resin, iglidur i3000. Its high resolution and precision in the DLP process for the production of wear parts particularly distinguish it. 'In the last two years, we have noticed that the demand for lubrication-free gears in various shapes and sizes is increasing. Resins are very suitable for this, as the process allows for injection-molding-like component quality,' explains Jonas Burk, head of the Additive Manufacturing division at igus GmbH. Therefore, igus has advanced its research in the field of synthetic resins and developed iglidur i4000, a material specifically suitable for the production of wear-resistant and precise gears. 'Especially during the pre-development phase, when it comes to proof-of-concept or proof-of-principle, the resin is suitable for gear prototypes, as production in the DLP process is fast and cost-effective. Adjustments can be made in the shortest time,' says Jonas Burk. The material is suitable for DLP, SLA, and LCD printers.
Service life increased by a factor of 5
Conventional resins, in addition to mechanical properties, are often not designed for wear and load in gear applications. 'Our resin has been specifically formulated to meet the requirements regarding performance, flexibility, and stability,' explains Jonas Burk. The iglidur i4000 resin was developed in close collaboration with customers and is characterized by high wear resistance and elongation at break, which is important as gears are subjected to constant load during movement. Tests in igus's own 5,500 square meter laboratory show that iglidur i4000 offers a 5 times longer service life and a 13 times higher elongation at break compared to i3000 and High Toughness resins. The self-lubricating properties of the material also allow for the elimination of grease or oil in the application, making the gear lubrication-free and maintenance-free. The new resin is already being used by the first customers.
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