Additive manufacturing with composite materials
The result then exceeded expectations after all. mayer-technology is on hand with full expertise to provide advice and support for all of the group’s production sites in Europe. One of the company’s goals is the central procurement, simplification and standardization of all spare parts.
This in turn has resulted in a technology hub, an online store through which all machine spare parts are already available to all Mayer Group sites throughout Europe. The additively manufactured machine spare parts are already sorted by packaging unit and can be ordered at the push of a button.
Availability, independence and innovation
mayer-technology is now facing gigantic savings itself. Numerous components achieve savings of up to 90%. The availability, independence and innovation possibilities of the company are thus now at a completely new level.
Missing design data is created by reverse engineering or manual drawing. The Markforged 3D printers offer an ideal solution, especially for discontinued or hard-to-find machine spare parts. With the precision, reliability and strengths, several hundred components can already be reasonably substituted today.
At mayer-technology, additive manufacturing thus already goes far beyond rapid prototyping and is already a fully-fledged manufacturing technology today!
How can plastic components achieve the necessary strengths?
mayer-technology relies on the composite fiber technology from the Markforged 3D printers Mark Two and X7.
The base material is Onyx. A PA6 with 15% carbon short fiber content. Via a second nozzle in the print head, the components can be reinforced using a continuous fiber made of carbon, aramite (Kevlar®) or glass fiber. Depending on the application, the different fibers offer different added value. The continuous fiber has only one starting and one end point per layer. The position of the fiber can be individually selected in the Eiger software.
So thanks to Markforged’s industrial 3D printers, carbon can now be used like a block of aluminum, achieving strengths that exceed aluminum, with excellent surface accuracy.
For larger components and parts made from Ulthem™ 9085 filament, Ralph Schneider will be using the new Markforged FX20 in the future.
Heavy Metal from the Markforged Metal X
With the Markforged Metal X system, components can be manufactured from different metals in a completely new form. The system also relies on the classic layering process. The components are then washed and sintered. In addition to 1.4542 stainless steel (17-4), copper (99.8%) and 1.7744 Inconel (625), various tool steels are also available. Even larger components, even shorter delivery times. The print farm of mayer-technology GmbH & Co. KG is growing steadily and currently already includes almost 20 3D printers.