The Dornbirn-based company 1zu1 is setting new standards in the production of intricate plastic parts with Fine Detail Resolution (FDR) in 3D printing. With a detail resolution of 0.05 millimetres, laser sintering technology enables the precise production of complex geometries that offer both mechanical stability and flexibility. Applications are mainly found in small series of electronic connectors, filters and medical products, which benefit from tool-free production and individual customization options.
An outstanding example of the use of FDR technology is the frame of the BionicBee from automation specialist Festo. The autonomous flying object, whose design is inspired by the swarming behavior of natural bees, requires an extremely lightweight yet robust construction. To achieve this, 1zu1 created a frame weighing just 3 grams and measuring 20 centimetres. This is made possible by the use of polyamide 11 (PA1101), which allows for filigree yet resilient structures. With struts just 0.9 millimetres thick, the design achieves a perfect balance of lightweight construction and stability.
“FDR is the perfect solution for electronic connectors, filters, screens and complex geometries in manageable quantities as well as for personalized medical technology products,” emphasizes Thomas Kohler, CEO of 1zu1.
“The results are visually equivalent to particularly detailed stereolithography, but many times more robust. The feather-light and flexible parts withstand take-off and landing without any problems,” explains Mattias-Manuel Speckle, Head of Additive Manufacturing Prototyping at Festo. “Innovations only succeed with reliable partners. At 1zu1, high quality, adherence to deadlines and clear communication go hand in hand.”
In addition to FDR technology, 1zu1 has also recently started offering hot lithography, a process that is suitable for manufacturing sterilizable and fire-resistant components. Supplemented by state-of-the-art SLS systems and automated post-processing systems, the company is positioning itself as a full-service provider for the production of prototypes and series components. “Whether high-end prototype or series product: we are a reliable partner for the production of 1 to 1,000,000 high-quality plastic components,” says Thomas Kohler.
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