High-precision, 5 times longer service life

Gears are the heart of many mechanical systems. They drive machines, enable precise movements in robots, and are indispensable in transmissions and automated systems. Customized and durable gears are in increasing demand. Therefore, igus has now developed a new 3D printing resin for the DLP process: iglidur i4000. This innovative material is specifically designed for the specific requirements of gears, has 13 times higher elongation at break, and offers up to five times longer service life than conventional 3D printing resins.

Three years ago, the plastics specialist igus launched its first resin, iglidur i3000. Its high resolution and precision in the DLP process for the production of wear parts are particularly distinguishing it. "Over the past two years, we've noticed an increase in demand for lubrication-free gears in a wide variety of shapes and sizes. Resins are ideal for this, as the process enables component quality similar to injection molding," explains Jonas Burk, Head of the Additive Manufacturing division at igus GmbH. Therefore, igus has advanced its research in the field of synthetic resins and developed iglidur i4000, a material specifically suited for the production of wear-resistant and precise gears. "Especially during pre-development, when it comes to proof-of-concept or proof-of-principle, the resin is ideal for gear prototypes, as production using the DLP process is fast and cost-effective. Adjustments can be made within a very short time," says Jonas Burk. The material is suitable for DLP, SLA, and LCD printers.

Service life increased by a factor of 5

Conventional resins, in addition to their mechanical properties, are often not designed for the wear and stresses encountered in gear applications. "Our resin was specially formulated to meet the requirements in terms of performance, flexibility, and stability," explains Jonas Burk. The iglidur i4000 resin was developed in close collaboration with customers and is characterized by high wear resistance and elongation at break, which is important because gears are subjected to constant stress during movement. Tests in the in-house 5,500 square meter igus laboratory show that iglidur i4000 offers a five times longer service life and 13 times higher elongation at break compared to i3000 and high-toughness resins. The self-lubricating properties of the material also mean that no grease or oil is required in the application, making the gear lubrication- and maintenance-free. The new resin is already being used by the first customers.