Additive

Manufacturing
3D printing using iglidur ®

Design
Guide
Design for quality
Design for manufacture
Design for function
Design for cost
Design for parts consolidation

...
plastics for longer life
®

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Your path to the ideal Design for quality

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Export 3D model for printing
tribo component Choose the highest possible resolution for your STL file
You have created the CAD model of your component. Now it's time to export the file for printing as an STL file.
Attention: select the highest resolution in the STL export setting to get the best possible print result. This is the
only way to ensure that the 3D printer, for example for printing gears, works out the tooth profile correctly. For
In order to achieve an ideal 3D printing result, it is important to consider limits of the process. your CAD model, make sure you avoid open contours, join multiple solids, and hide surfaces and sketches. If
The objects must fit in the manufacturing space (220mm x 170mm x 300mm). For gears, the you do not have your own CAD programme, you can use the igus® CAD configurators for plain bearings, rollers,
gear modules must not be smaller than 0.5mm, and the tooth head thickness not less than gears and racks for your tribo parts at www.igus-cad.com.
0.4mm. The wall thickness of components must not fall below 0.7mm. Ensure that you work
in CAD models with integer multiples of the 0.1mm layer thickness - an adaptation to 0.05mm
is only possible in a few cases. If you want to mark components with information, you can use
engraving (at least 0.5mm) or a constructive font (≥ 0.5mm). Process:
To minimise rework, openings such as holes and slots should be straight - if necessary, all
conical for long holes. In addition, make sure that internal channels can be reached with the Problem:
drill to remove the printing powder (alternative: multiple division of the component). Note that CAD data quality poor/too low resolution
Solution!
reworks such as chemical smoothing can result in deviations of up to 0.4%. Adjust STL export settings!
Process:
all
Problem:
Design for quality CAD component defects, such as open
Ensure sufficient data quality, which directly affects component quality and function contours and multiple shells, can lead to body
separation in the laser sintering process
Design for manufacture Solution!
Create a production-oriented CAD model, keeping an eye on the process limits Finally join components consisting of several
solids; hide surfaces and sketches
Process:
Design for function SLS
to be avoided
Ensure the desired component functionality Problem:
Shrinkage, curling of components due to different
wall thicknesses and high length ratio (L/d)
Design for cost Solution!
preferred
Optimise your component from an economical point of view: Provide even wall thicknesses, if necessary,
Costs, material consumption and production time execute ribbing or multiple parts possible

Design for part consolidation Process:

Benefit from the entire design freedom of additive manufacturing for functional integration, reduction all (mainly laser sintering) poor
of parts and assembly costs Problem:
The gear has a rough profile and/or does not run neatly
Solution!
Pay attention to the best possible export quality of the
gear model in the CAD system. Make sure radii and
the tooth profile are completely and neatly displayed. good
Alternative: use of the igus® gear configurator!

Process:
SLS
Problem:
The adjustment of the hole diameter in the data processing is
made more difficult by rounding due to software
Solution! poor good good
Omit rounding or use chamfer. Rounding as far as possible
only if functionally absolutely necessary

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Design for manufacture
Make CAD model
Pay attention to manufacturing space, wall thickness, layer thickness and reworking
Would you like to produce your additive manufactured component as cost-effectively and time-efficiently as
Process:
possible? Design for manufacture deals precisely with this topic - economical and design-oriented adjustments
SLS
to your component, which are adapted to the igus® 3D printing process. The following illustrations demonstrate Problem:
what you have to consider in terms of manufacturing space, wall thicknesses and layer thicknesses. Furthermo- Inner channels cannot be freed from powder
re, we will point out which design guidelines you should internalise in terms of reworking. Solution!
Drill a hole of at least 3mm, widen the channels on
the inside so that it is easier to remove the powder/
Process: make the component in several parts so that the
SLS/FDM
channels are open.
Problem:
The part does not match the model: some features are wrong
or not implemented at all
Solution! Manufacturing space Process:
The process limits must be observed: maximum manufacturing SLS printer SLS
space 220x170x300mm / smallest features and wall thickness 220 x 170 x 300mm Problem:
min. 0.7mm, manufacturing tolerance size-dependent for Component variants are difficult to distinguish/logo
component dimensions up to 50mm: ± 0.1mm, moreover ± or label should be attached
0.2%, adaptation to 0.05mm possible in some cases, design in Solution!
average tolerance Fonts engraved:
≥ 0.5 mm, font height > 5 mm
Process: Constructive fonts:
all (mainly laser sintering) ≥ 0.5 mm, font height > 6 mm
Problem: independent of orientation (smaller fonts are
Teeth of the gear are not properly developed or not functional feasible in the x/y-direction)
Solution!
Note the process limits for laser sintering of gears:
Minimal tooth module: 0.5mm Process:
Minimum tooth head thickness: 0.4mm SLS
Max. outer diameter: 172mm Problem: RZ [μm] Ra [μm]
Rmax
The surface quality is not sufficient for the intended [μm]
application Nature,
Solution! glass bead 80 – 125 20 – 30 240
Process: blasting
all If necessary, request the following reworking
Problem: procedures to achieve the specified surface Vibratory finishing* n.b. 15 120
Small structures/wall thicknesses below 0.7mm and general characteristics:
component dimensions that are built in Z-oriented colouring Chemically pol- n.b. 10 n.b.
Solution! surface machining ished
Dimensional variations must, if possible, be constructed Chemical polishing
in whole layer thicknesses, that is as a rule, 0.1mm layer Vibratory finishing
thickness. (No dimensions with 0.0x, especially when oriented
in Z-direction).
Process:
SLS
Process:
Problem:
SLS
Problem: Parts that are too big for the manufacturing space
Small holes are closed or cause rework cannot be manufactured
Solution! Solution!
If possible, select the hole diameter depending on the depth Divide component and provide joint geometry
in order to avoid reworking, if necessary widen the holes (form-fitting), which allows a precise assembly
conically during bonding

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Design for function
Make CAD model
Design for cost
Think additive - save costs
Make sure that geometries work Consider material recesses
Make sure all functional elements are correctly designed. Example of threaded component: while some CAD 3D printing gives you the opportunity to save production costs. Unlike conventional manufacturing processes
programmes illustrate a threaded texture, they do not make it part of the 3D model. The printed part then has a such as machining, complex geometries can be implemented in additive manufacturing without additional cost.
non-functional hole. Pay attention to consciously design the geometry - or get that done by igus®. We implement The process does not require expensive special tools. So think additively and only add material where it fulfills a
printable thread sizes from M6 upwards. In addition, we recommend a thread clearance of +0.3mm at the dia- function - for example, in the gear, where you place sufficiently sized spokes instead of a solid disc.
meter for lead screw nuts, and a clearance of +0.1mm at the thread flank in the Z direction. For the best possible
function in interlocking structures, a gap of 0.2mm is recommended.
Process:
SLS
Problem:
Process: High component costs due to high volume, material
all M3 M4 M5 M6 M8 unnecessary
Problem: Solution!
The printed part should receive a functional thread Hole
Save material where reasonably possible
diame- 4.7 6.1 7.5 9.2 11.2
Solution! ter Use braces instead of solid material for rigidity
Use one of the following options: min. Prefer thin-walled construction (see injection
6 8 10 14 15 Volume: 100% Volume: 40.3%
Let threads be cut (M1.6 – M6) depth
moulding)
Provide threaded insert, see table (M3 – M8)
Design printable threads (from M6) Process:
SLS, FDM
Process: Problem:
all The part is not optimal (in terms of cost, function,
Problem: etc.), since a production-oriented design was
Threads are inserted into CAD, but are not included in the selected for conventional methods
printed part Solution!
Solution! Production-oriented design for additive
CAD illustrates thread texture to indicate threading in the manufacturing: "Additive Thinking". Only add
drawing (left picture). However, the 3D model contains no material where it is needed. Perform analysis based
matching geometry, so the part has only one hole in the result. on the functional areas
The thread must be designed (right picture) - by the customer
or by igus®. Printable nut size from M6

Process:
SLS
Design for parts consolidation
Think additive - save costs
Problem: Make your component multifunctional
Parts that interlock and are designed precisely to size do not 3D printing is a production technology that allows you to implement complex geometries at no extra cost. It is
match therefore advisable to equip the component with as many functions as possible, thereby reducing part costs
Solution! and assembly costs. For example, optical instructions for operation, bearing points, sprockets for belt drives,
Interlocking structures provided with the appropriate gap size.
snap hooks, logos or addresses can be integrated. Complexity plays (almost) no role - unlike traditional methods
A distinction is made between assemblies produced in one
piece (here 0.4-0.5mm gap, right picture) and individually built such as milling.
components (here 0.2mm gap, left picture).

Process:
Process: SLS
SLS Problem: Logo isual operating
V
Problem: Assembly costs and parts costs
Reinforcement ribs instructions
Printed drive nuts run poorly or not at all on the lead screw Solution!
Solution! Functional integration: integrate as Drive pulley for Flexible snap-on hooks
Thread clearance at the diameter (D1 and D4): +0.3mm many functions as possible in one belt drive Thin-walled to
Thread flank clearance in the Z direction: +0.1mm component - complexity plays Bearing points save material
Printing of drylin lead screw geometries can be requested (almost) no role

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/9001:2015
/16949:2016
igus® is certified in accordance with ISO 9001:2015 and IATF 16949:2016 in the
field of energy supply systems, cables and harnessing, as well as plastic bearings.

Do you have any questions about additive manufacturing?

Contact us:

Tom Krause
Head of Business Unit
Additive Manufacturing
Phone: +49 2203 9649 975
e-mail [email protected]

igus® GmbH Spicher Strasse 1a 51147 Cologne, Germany

Phone: +49 2203 9649-9806 Fax +49 2203 9649-7691
[email protected] www.igus.eu

© 2019 igus® GmbH

Subject to technical alterations. MAT0074508.20