Plastics News - Show Daily - October 17, 2023 - 8

8 * Plastics News, October 17, 2023
FAKUMA SHOW DAILY
Additive manufacturing, injection molds, ensure 1zu1 growth
By David Vink
Plastics News Correspondent
Additive
manufacturing
cialist
Dornbirn,
speAustria-based
1zu1
Prototypen GmbH & Co KG
opened in 1996 and has grown
from 2.6 million euros in sales and
15 employees in 2000 to 17 million
euros and 160 employees this year.
1zu1 operates 20 3D printers, seven
EOS selective laser sintering machines
and 20 vacuum casting units.
AMT Postpro SF10 and DyeMansion
Powershot Dual Performance
surface cleaning and smoothing
equipment was added in 2023, increasing
the number of post-processing
units to eight, according
to Markus Schrittwieser, 3D printing
and additive manufacturing
manager. The 20 injection molding
machines with 10-160 metric
tons of clamping force come from
Arburg and SHI Demag.
SLS projects
Schrittwieser and Dario Loss,
project manager tooling, talked
about SLS and injection molding
of a 32-by-32-by-18-millimeter
plastic sewing machine spool cap.
Injection molding including mold
investment is more expensive
for 100 spool caps, at 19.86 euros
each, compared with 2.80 euros
with 3D printing.
Breakeven occurs at 7,500 parts
with 1.85 euros. Injection molding
becomes cheaper after that volume,
at 1.52 euros for 10,000 parts,
while SLS only drops to 1.80 euros.
Schrittwieser is proud of a 15year
SLS project with Tägerwilen,
Switzerland-based Storz Medical
AG. Development kicked off in
2008 in substitution of a milled aluminum
air diffuser within a shock
wave therapy device with a twopart
equivalent made by SLS in
EOS PA2200 laser sintering nylon,
assembled with four screws. This
resulted in a trial series in 2012
and serial production in 2014.
Single-part trials started in
2018, and full production starting
in 2022 saved 60-70 percent over
the original milled aluminum part,
Schrittwieser said.
1zu1 has produced more than
50,000 air diffusers in the new
complex, lightweight, space-saving
airfl ow optimized design, integrating
channels, undercuts and
chambers. 1zu1 said the P500 machine
used is the fastest SLS machine
worldwide. Schrittwieser
revealed that it weighs 7.5 tonnes
and costs around 700,000 euros.
Injection molding
project
For the E-vita Open Neo stent
graft system of the Hechingen,
Germany-based EU production
plant of the U.S. medical products
company Artivion Inc., 1zu1 fi rst
3D printed samples in spring 2018.
It produced the fi rst injection
1ZU1 PROTOTYPEN
GMBH & CO KG
Hall A5, Booth 5112
molded sample parts from aluminum
pilot molds by summer 2018.
Following mold optimization,
1zu1 produced 12 serial production
molds for each of the 12 components
involved. 1zu1 uses them to
produce the parts in an ISO Class 8
clean room, covering a 1,500-2,000
parts per year requirement.
Loss said the time frame from
initial sampling to the validation
phase and then series production
was just 16 months, " a blink of
an eye in the medical technology
sector. " Artivion project engineer
Yannick Röcker revealed that a
second product for the U.S. market,
with some optimization and
orange components replaced by
turquoise ones, was due to go
into production in mid-2023.
Mold making
1zu1 produces only aluminum injection
mold tools, which, at 8,00010,000
euros on average, are about
25 percent less expensive than
steel molds for 10,000 parts. Loss
talked of four-week rapid tooling,
compared with four to six months
for steel molds, but said aluminum
molds are limited to 150° C melt
1zu1 produces only aluminum
injection mold tools, which, at
8,000-10,000 euros on average, are
about 25 percent less expensive
than steel molds for 10,000 parts.
1zu1 Prototypen GmbH & Co KG photos
temperature
thermoplastics.
He
said aluminum molds can produce
25,000 polystyrene parts, but mold
coating extends this by fi ve to 10
times. 1zu1 sometimes uses steel
mold inserts to extend mold life.
Special show off er for FAKUMA 2023 -
20% off annual subscription
Subscribe today!
www.sustainableplastics.com
SP Subs half page ad for Fakuma Show daily.indd 1
05/10/2023 07:42
http://www.sustainableplastics.com

Plastics News - Show Daily - October 17, 2023

Table of Contents for the Digital Edition of Plastics News - Show Daily - October 17, 2023

Plastics News - Show Daily - October 17, 2023 - 1
Plastics News - Show Daily - October 17, 2023 - 2
Plastics News - Show Daily - October 17, 2023 - 3
Plastics News - Show Daily - October 17, 2023 - 4
Plastics News - Show Daily - October 17, 2023 - 5
Plastics News - Show Daily - October 17, 2023 - 6
Plastics News - Show Daily - October 17, 2023 - 7
Plastics News - Show Daily - October 17, 2023 - 8
Plastics News - Show Daily - October 17, 2023 - 9
Plastics News - Show Daily - October 17, 2023 - 10
Plastics News - Show Daily - October 17, 2023 - 11
Plastics News - Show Daily - October 17, 2023 - 12
Plastics News - Show Daily - October 17, 2023 - 13
Plastics News - Show Daily - October 17, 2023 - 14
Plastics News - Show Daily - October 17, 2023 - 15
Plastics News - Show Daily - October 17, 2023 - 16
Plastics News - Show Daily - October 17, 2023 - 17
Plastics News - Show Daily - October 17, 2023 - 18
Plastics News - Show Daily - October 17, 2023 - 19
Plastics News - Show Daily - October 17, 2023 - 20
Plastics News - Show Daily - October 17, 2023 - 21
Plastics News - Show Daily - October 17, 2023 - 22
Plastics News - Show Daily - October 17, 2023 - 23
Plastics News - Show Daily - October 17, 2023 - 24
https://www.nxtbookmedia.com