Please choose your delivery location

The selection of the country/region page can influence various factors such as price, shipping options and product availability.

View all locations

Go to www.igus.com

My contact person

Select location

After selection of your ZIP code, we designate the relevant staff to attend to you at once.

Rapid prototyping
with plastic gears

Electric Vehicle Charging Innovation: High-Performance Polymers for Superior 3D Printed Gears

Profile

What was needed: plastic gears for prototypes
Manufacturing process: igus 3D printing service
Requirements: wear resistance, robustness, fast delivery
Material: iglidur i6
Industry: automotive
Success from the collaboration: time savings thanks to simple online configuration and fast delivery, elimination of tooling costs, variety of options

Easelink, based in Graz, Austria, has developed the "matrix charging" system, which consists of two components. A charging pad is connected to the mains is installed in the parking spot. A connector on the bottom of the e-car drops down when the car is parked over the pad. The charging process starts automatically, so the driver does not have to connect a cable – like inductive charging, but with 99 percent efficiency and up to ten times the charging power.During the development process, the design engineers created a production-ready component by means of several prototypes. To minimise expenses while ensuring high quality, they used the igus 3D printing service.

Save time and money with the igus 3D printing service

E-mobility represents the future of transportation, with electric vehicles (EVs) at its core. However, their widespread adoption has been hindered by a lack of robust charging infrastructure. Recognizing this gap, Easelink aims to revolutionize the market with its 'Matrix Charging' system. This innovative solution comprises a charging pad linked to the power grid, installed in parking areas, and a connector attached to the EV's underside. When parked above the pad, the connector lowers automatically, initiating the charge without the need for manual cable connection. This system not only offers convenience akin to inductive charging but also boasts a remarkable charging speed—up to tenfold—and an efficiency of 99%. The journey to a market-ready product involved iterative prototyping, a process that can escalate in cost and time, potentially becoming a bottleneck. Nevertheless, Easelink navigated this phase with agility, utilizing 3D printing technology to fabricate the intricate gears within the connector prototypes, thereby streamlining the development process.

Matrix Charger with 3D-printed gears made of iglidur material with an electric car

Configured quickly online

Designing gears online for igus' 3D printing service is a swift process, taking roughly 60 seconds. The delivery process commences within 24 hours, and gears crafted using industrial printers are dispatched within three days. Hermann Stockinger, the founder of Easelink, emphasizes the importance of flexibility and rapid delivery in prototype construction, qualities he finds exemplary in igus. The online configurator's ability to quickly produce various gear designs is highly valued. Another significant benefit is the cost-effectiveness of igus' service, attributed to the absence of tooling expenses. A design engineer simply selects the gear module, specifies the number of teeth, and the required torque transmission. The configurator then generates a 3D model, which serves as the foundation for 3D printing. This system allows for the creation of hundreds of single and double gear variants without the need for CAD software.

Matrix Charger with 3D-printed gears made of iglidur material

iglidur i6 for high wear resistance

The most suitable material for gears is the iglidur I6. The high-performance plastic withstands ambient temperatures of -40 to +80 degrees Celsius, is pressure-resistant up to 44 MPa and has a high wear resistance. It was proven in laboratory tests that it is significantly more robust than the classic plastic polyoxymethylene (POM). Here, gears were operated at 12 revolutions per minute (RPM) and loaded with 5 Nm torque. The result: The 3D printed gear made of iglidur I6 was still fully functional after a million cycles, and the wear hardly measurable. Unlike a machined gear made from POM. It was worn out after 321,000 cycles and broke down after 621,000 cycles.

Buy laser sintering material iglidur I6 online

Further application reports

Formula Student racing cars with customised plastic pinions made of iglidur® high-performance polymers

Custom-made component made using the igus® 3D printing service

Inspired by Formula 1, the student teams of the "Formula Student Germany" construction competition compete with each other. For constructing their racing cars, the Formula Student Team from Weingarten near Ravensburg needed customised plastic pinions, amongst other things. With the 3D print service by igus®, these components were not only produced quickly, but also made of wear-resistant iglidur® material.

Individual component printed fast and easily

3D-printed grippers for the cosmetics industry

Printed in 3D: maintenance-free gripper for the packaging industry

Fast availability at a low price and use under hygienic conditions were important prerequisites for this 3D printed gripper. It is used to package cosmetic products and has the special advantage of working without additional lubrication, hence fulfilling hygienic requirements.

More flexibility through 3D printing

3D printed component for camera motion systems

Printed in 3D: customised plain bearing ready for collection within hours

What do you do when an important replacement part for an exhibit suddenly goes missing on the way to a trade show? The response of the Berlin-based company Blackcam, a manufacturer of camera motion systems, is to turn to the igus 3D printing service.

Cost-effective and available quickly

Country/Region

By selecting your country you will be shown local offers and information.

Language settings

Select preferred language: