Integrated solid lubricants for lubrication-free prams - spare parts from the 3D printer simplify disassembly

• What was needed: Lubrication-free bearings
• Manufacturing method: Selective laser sintering
• Requirements: Good sliding properties, high wear resistance, long service life
• Material: iglidur i3
• Industry: Transportation
• Success from the collaboration: No external lubricant required, simple assembly and disassembly, durable plain bearings

 
The application at a glance:
In order to save enough space to transport a tram in the car, many manufacturers have equipped the trams with detachable components. For example, the wheels can be pulled out of their bearings. However, the machined metal ends of the wheels, which are inserted into the plain bearings, are lubricated. This means that lubricant can get onto the user's clothing or hands during disassembly. To eliminate that problem, Tom Krause, head of additive manufacturing, traced the bearing and printed it using the laser sintering process. The iglidur i3 material, specially developed for laser sintering, is well suited to the component because the integrated solid lubricants make external lubrication unnecessary. In addition to the good sliding properties, components made of iglidur i3 last up to 50 times as long as regular 3D printing materials.
 

The application example in the video provides the explanation

Problem

Prams are often designed in such a way that they can be dismantled in a few easy steps to save space when stowed in the boot of the car. This also means that the tyres can usually be simply pulled out of their bearings. The problem with much of the design: the metal pins that are inserted into the plain bearings are lubricated and can soil hands or clothing during disassembly. In addition, the tyres must be stowed separately in plastic bags or similar containers, otherwise they run the risk of drying out.

Solution

The solution to this problem was quickly found in Cologne in the 3D printing department of igus. Tribologically optimised materials for additive processes are developed there, including the iglidur I3 material, which is specially produced for laser sintering. After the head of additive manufacturing, Tom Krause, had measured the old bearing and created a CAD model from it, the printing of the component was also quickly done. The new bearings made of iglidur I3 convince with the integrated solid lubricants, which make external lubrication superfluous. In addition, the good sliding properties and high wear resistance of the material are well suited for the bearing points of the pram.

Lubrication is not always practical

Anyone who has children knows the situation: for excursions and on holiday, the pram has to fit in the boot of the car. The best way to do this is with prams that can be dismantled into their individual parts in just a few steps. In individual cases, it turned out to be a very complicated task because of the lubricated machined ends on the wheels. Hands and clothes were full of grease and the wheels had to be packed again individually in plastic bags so that the grease would not still get on the interior of the car and dry out the machined ends.

Lubricated components on the pram are often not so easy to transport

With iglidur I3 to the perfect (and cost-effective) spare part

It was possible to trace the bearings for the lubricated machined ends relatively quickly and to manufacture them additively with the most suitable material for this purpose. Additive manufacturing saves resources and is particularly cost-effective, as no other tools are required apart from the 3D printer and the printing material. This makes cost-effective printing possible with no minimum order quantity. In addition to simple components, 3D printing can also produce more complex components in a single process. It is particularly valuable for individual customer applications. In combination with igus' own high-performance polymers, individual components can be commissioned from the igus 3D printing service that precisely meet the requirements of their application. The common component of the sliding-optimised plastics is the integrated solid lubricants, which make grease superfluous. In principle, components made of igus plastics show less wear and better sliding properties than conventional plastics.
Also in this case, the plain bearings made of iglidur I3 still operate perfectly and reliably even after 4 years.

Due to the integrated solid lubricants, the materials from igus are ideally suited for lubrication-free operation