SK Industriemodell presents 3D-printed tools at Formnext

At Formnext 2024 in Frankfurt, SK Industriemodell GmbH will be presenting innovative 3D-printed tools and processes designed to significantly shorten and improve development cycles for prototypes and components.

In Hall 11.1, Stand F69, the company will be demonstrating how 3D printing and hybrid production processes can be used to design prototypes faster and more efficiently. There will be a particular focus on the so-called “Print & Inject” process, also known as “Freeform Injection Molding”, which enables the flexible production of highly complex components.

“Companies in numerous industries are faced with the challenge of having to design their approach and processes in research & development and product development faster, better and more effectively when manufacturing series tools, prototypes, components and products. At Formnext, we will be presenting 3D printed tools and processes that shorten iteration loops with series material, reduce the need to change the design of a series tool and realize extremely detailed representations and filigree geometries within a component,” explains Sebastian Krell, Managing Director of SK Industriemodell GmbH.

In live operation at the trade fair, the process will be demonstrated on two injection molding machines from Dr. Boy. An impeller weighing 1.3 grams will be produced on a BOY XXS using a 3D-printed tool with detachable inserts. The “Print & Inject” process offers the advantage of eliminating storage and maintenance costs for tools, as the 3D-printed tools can be adapted or replaced directly if necessary.

“The ‘Print & Inject’ process offers added value in both one-off and reusable 3D printed tools. Among other things, storage and maintenance costs for injection molds or spare parts are eliminated. In addition, prototypes and components can be produced in almost all standard injection molding materials,” says Krell.

The “Hybrid Tooling” process will also be presented on a BOY 25E. This involves the use of a 3D-printed tool mold that is partially reinforced with aluminum to enable repeated use. This method allows the production of prototype parts from PA66, a common material in injection molding. Particularly noteworthy is the 3D-printed insert in the undercut area, which dissolves after the injection process, allowing a high degree of flexibility in component design.

“The ‘hybrid tooling’ process combines the best of two technologies. Part of the cavity is milled from aluminum to make the tool reusable. A special feature is the finishing of the component. A 3D printed insert is inserted in the undercut area of the component, which can be dissolved after the injection process,” explains Krell.

Departments in research and development as well as the plastics and medical technology sectors in particular benefit from this technology. The process is also of interest to universities and research projects, as Krell emphasizes: “This is where our long-standing partnerships in research projects with RWTH Aachen University come into play. The ‘Print & Inject’ process supports the efforts of the Central Innovation Program for SMEs (ZIM) to bring innovative ideas into daily use and generate added value for relevant target groups.”