{"id":4851,"date":"2021-08-10T08:08:00","date_gmt":"2021-08-10T08:08:00","guid":{"rendered":"https:\/\/ultimakerstage.wpengine.com\/learn\/"},"modified":"2023-10-25T21:51:31","modified_gmt":"2023-10-25T21:51:31","slug":"haenssler-group-leveraging-kimya-abs-esd-filament-with-the-ultimaker-open","status":"publish","type":"post","link":"https:\/\/ultimaker.com\/nl\/learn\/haenssler-group-leveraging-kimya-abs-esd-filament-with-the-ultimaker-open\/","title":{"rendered":"Haenssler Group"},"content":{"rendered":"
\"haenssler-kimya-hero\"<\/div>\n

Haenssler Group<\/h1>\n

Leveraging Kimya ABS-ESD filament with the Ultimaker open filament system<\/h2><\/div><\/div><\/section>\n

In the summer of 2020, Haenssler Group \u2013 a German company that develops and produces unique sealing solutions and complex parts from high-quality plastics and elastomers \u2013 began designing and producing a part for one of its customers. This customer was seeking a sealant with anti-electrostatic properties that could provide thermal protection between two components of a machine.<\/p><\/div>\n

This part had to be composed of two separate components that could be easily removed and reassembled during the life cycle of the machine. Further adding to the challenge, the customer required 300 of these parts for integration within an existing production line. Production was to be done twice yearly, in small batches of 150 each, all while adhering to a precise delivery schedule. <\/p>\n

With this in mind \u2013 and because its filaments are compatible with Haenssler Group\u2019s Ultimaker S5 3D printer<\/a> \u2013 Haenssler Group teamed up with 3D printing material manufacturer Kimya.<\/p><\/section>\n

\"3D<\/figure><\/div>\n
Removing the part from the 3D printer<\/div><\/div>\n
\"Ultimaker<\/div>\n
3D printing with Kimya ABS-ESD<\/div><\/div><\/section>\n

Moving forward with Kimya ABS-ESD filament\u00a0<\/b><\/h2>\n

Kimya ABS-ESD filament is an engineering-grade material\u00a0that proved to fulfil the necessary requirements, while\u00a0being processable on desktop printers such as the Ultimaker\u00a0S5.\u00a0<\/p>\n

The ABS matrix upon which the filament is based ensures adequate\u00a0resistance to impact\u00a0(Charpy,\u00a010.9\u00a0KJ\/m\u00b2)\u00a0and heat\u00a0(up to 90 \u00b0C), in\u00a0combination with typical neat ABS tensile\u00a0modulus and strength value (see Table 1).\u00a0<\/p>\n

Kimya ABS-ESD\u2019s proprietary\u00a0fillers\u00a0and compounding technology\u00a0enable ESD performance\u00a0to stabilize around\u00a010^6 ohm\/sp\u00a0nominal value for the 11 months\u00a0following compounding.\u00a0Additionally,\u00a0to guarantee that the\u00a0same\u00a0ESD performance is\u00a0preserved\u00a0in the\u00a0106-109\u00a0ohm\/m\u00b2\u00a0range for each production batch, surface resistivity\u00a0is assessed\u00a0(ASTM 527 standard on 3D printed specimen)\u00a0prior to\u00a0each\u00a0batch commercialization.\u00a0<\/p>\n

Interestingly, filament diameter is also known to have a remarkable\u00a0effect on ESD behaviour reproducibility. The narrow\u00a0dispersion\u00a0of\u00a02.84 mm\u00a0\u00b1\u00a00.0062 mm (99.999936%\u00a0confidence\u00a0interval)\u00a0in\u00a0filament diameter\u00a0of Kimya ABS-ESD enables\u00a0flawless extrusion volumes and height\u00a0layer-stacking, prior to\u00a0melt solidification.\u00a0<\/p>\n

Therefore,\u00a0control over filament diameter is of\u00a0even higher\u00a0importance\u00a0when\u00a0processing ESD material<\/a>, as irregular surface topology and under-extrusion\u00a0effects\u00a0can\u00a0heavily\u00a0mine efficient and homogenous charge transport\u00a0throughout\u00a0the surface of the 3D printed part.<\/p>\n

The electrical and mechanical properties for a Kimya ABS-ESD printed specimen are shown in the table below.
<\/p><\/section>\n

Test method<\/th>\nStandards<\/th>\nValues<\/th><\/tr><\/thead>\n
Surface resistivity<\/td>\nASTM D257<\/td>\n107\u202f- 109\u202fOhms\/m\u00b2<\/td><\/tr>\n
Tensile modulus<\/td>\nISO 527-2\/5A\/50<\/td>\n1,121 MPa<\/td><\/tr>\n
Tensile Strength<\/td>\nISO 527-2\/5A\/50<\/td>\n24.3 MPa<\/td><\/tr>\n
Tensile strain at yield<\/td>\nISO 527-2\/5A\/50<\/td>\n3.1%<\/td><\/tr>\n
Tensile Stress at Break<\/td>\nISO 527-2\/5A\/50<\/td>\n19.8 MPa<\/td><\/tr>\n
Tensile strain at break<\/td>\nISO 527<\/td>\n6.4%<\/td><\/tr>\n
Charpy impact resistance<\/td>\nISO 179-1\/1eA<\/td>\n10.9 kJ\/m\u00b2<\/td><\/tr>\n
Shore Hardness<\/td>\nISO 868<\/td>\n66.7D<\/td><\/tr><\/tbody><\/table><\/section>\n
\"haenssler-chart-1\"<\/figure><\/div>\n
A) Process capability for filament X-direction<\/div><\/div>\n
\"haenssler-chart-2\"<\/figure><\/div>\n
B) Process capability for filament Y-direction. Calculations are based on he Weibull Distribution Model.<\/div><\/div><\/section>\n

A bespoke printing profile<\/b><\/h2>\n

Kimya\u2019s ABS-ESD filament, Haenssler Group decided, also met two essential criteria: anti-electrostatic (ESD) resistance<\/a>, as well as temperature resistance<\/a> for up to 90\u00b0C. Another benefit was the filament\u2019s weight. At just 2.2 kg per reel, Haenssler Group was able to more efficiently transport and handle the material, saving the company both time and money.\u00a0<\/p>\n

With the right material in hand, Haenssler Group began the part\u2019s design<\/a> phase, optimizing its insulating properties by incorporating an internal vacuum. When printing, however, Haenssler Group observed several imperfections due to delamination marks and flow defects, which sometimes occur when printing large-format parts with complex geometries. Haenssler Group notified Kimya, requesting analysis of the problem \u2013 as well as a proposal for a solution \u2013\u00a0which came in the form of a bespoke printing profile.<\/p>\n

“When we encountered printing defects, Kimya reacted quickly to establish a printing profile able to deliver the required level of quality. We were therefore able to produce the parts within the deadline,”\u00a0Dirk Olbert, a 3D Engineer at Haenssler Group, said.<\/p>\n

Using the material\u2019s printing profile enabled Haenssler Group to more quickly validate the final part\u2019s properties \u2013 an overarching benefit that enables the company to readily adapt to continuously changing market demands. It also shines a spotlight on 3D printing \u2013 showing that the technology offered by affordable and reliable 3D printers, in combination with high-quality and hardware-validated materials, can increase productivity and reduce product (or service) time-to-market.<\/p><\/section>\n

\"haenssler-isolator-part-data\"<\/figure><\/div>\n
3D model of Haenssler isolator part (left), and statical analysis of the six most representative dimensions of the model for all 10 samples selected. Target dimension is highlighted with a red dotted line.<\/div><\/div>\n

A plan to scan<\/b><\/h2>\n

ESD-safe performance is highly influenced by the presence of surface defects, which would inevitably alter the dissipation of charges. This meant Haenssler Group\u2019s parts must be reproducible for both ESD behavior and dimensional accuracy, in addition to meeting visual and integrity requirements.<\/p>\n

Of the 300 units produced yearly by Haenssler Group,\u00a0a group of 10 specimen printed on multiple\u00a0Ultimaker\u00a0S5 3D printers was selected to undergo\u00a0a manual\u00a0dimensional analysis, by means of a\u00a0caliper,\u00a0of the most-representative\u00a0features.\u00a0The graphs below\u00a0show a minimal variation (below \u00b1 0.2 mm) from the target dimensions\u00a0A,B,C,E,F and\u00a0a\u00a0predictable variation of -0.3 mm from the target of 8mm for dimension D. Overall, all the samples reported a good level of precision and batch-to-batch reproducibility, as shown by the negligible variations in all dimensions tested between different samples.<\/p><\/section>\n

\"haenssler-color-map\"<\/figure><\/div>\n
A color map showing a pass\/no pass analysis of \u00b1 0.3 mm for dimensional accuracy, made via a 3D scan of the Haenssler isolator part<\/div><\/div>\n

To fully assess the surface quality of the whole printed object, Haenssler Group engineers performed a high-resolution 3D scanning analysis on a select number of printed parts, using a GOM Atos Core 3D scanner.<\/p>\n

The scan generated a color map showing relative deviations between the ideal CAD model and the actual scanned part. It then generated a pass\/no pass filter for dimensional accuracy, with a threshold of 0.3 mm. Red-marked areas on the map, randomly spread along the Z-direction of the cylindrical area, originated from sub-millimetric residue (deviations of more than 0.3mm). This residue was eliminated with minimal and simple post-processing using P240 sandpaper, and sufficiently removed surface defects and eliminated potential accumulation points for electrical charges.<\/p>\n

This enabled Haenssler Group to create an ABS-ESD optimized printing profile, which, in combination with a properly calibrated Ultimaker S5, resulted in parts with acceptable tolerance limits and with little batch-to-batch dimensional variation.
<\/p><\/section>\n

\"Measuring<\/figure><\/div>\n
Measuring a Kimya ABS-ESD 3D printed part<\/div><\/div>\n

Partner power<\/b><\/h2>\n

As\u00a0established\u00a0by the topography and\u00a0dimensional analysis,\u00a0Kimya ABS-ESD\u00a0processability\u00a0on\u00a0an Ultimaker\u00a0S5 printer \u2013\u00a0in combination with its controlled ESD behaviour\u00a0\u2013\u00a0enabled\u00a0Haenssler Group to validate 3D printing as a manufacturing\u00a0technique to produce medium-volume batches of isolator components.\u00a0Together, Kimya, Haenssler Group, and Ultimaker \u2013\u00a0via its accurate 3D printers<\/a> and open filament system \u2013\u00a0were able to develop a bespoke solution to a highly specific customer demand. Additionally, Haenssler Group reported a 60-80% reduction in material waste in cost per part when compared to traditional milling.<\/p>\n

The project was also able to be completed in a relatively short period of time \u2013\u00a0enabling the customer to continue production without interruption.<\/p>\n

“Our partnership with Kimya has been highly beneficial,\u201d Adrian Heinrich, Marketing Manager at Haenssler Group, said. \u201cKimya\u2019s team have demonstrated its reliability and expertise, especially given the highly challenging nature of the project. We are certain that we will collaborate further in the future, using its 3D filaments for other projects.”
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Learn more about the material<\/span><\/a><\/div>\n