Rapid prototyping from silicone
Elastic seals from the 3D printer - prototypes made of silicone
The 3D printing process can be used to produce three-dimensional seals layer by layer based on CAD data sets for testing purposes . Physical or chemical hardening processes take place while the seals are being printed. We typically use a silicone-like printing material for elastic prototypes . KREMER can print flexible prototypes from a silicone-like material with a hardness of 35 Shore A or 65 Shore A. The prototypes, which can be made from either of the two materials, are very similar to the functionality of a molded silicone seal.
With the 3D printer we can also produce prototypes of profile seals up to a length of 300mm.
The time-consuming production of injection molds and extrusion tools is no longer necessary; the 3D printer creates the desired part virtually from nothing.
Only order the production of series tools and initial samples made from them after testing a prototype produced using inexpensive 3D printing. Not only do you gain a high level of flexibility in the design and development phase, but you can also optimize the properties of your product in many different ways.
For flat gaskets, which are only required in small quantities, such as prototypes , it is usually not worth building a punching tool. Another advantage is that the cutting patterns of the prototypes made from sealing and insulating materials are not concave. Furthermore, standard plates, rolls and blocks can be used for water jet cutting.
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Cutting seals using a plotter is done using a movable blade that is attached to a CNC-controlled swivel head. An individual tool is therefore not required for plotting flat seals . Compared to other cutting techniques, smaller cutting tolerances are possible with plotter cutting, which is why the process is particularly suitable for very thin and soft materials. A so-called “kiss cut” is also possible here, whereby only the material is cut without damaging the carrier or protective film.
Laser cutting of thin-walled seals is suitable for both prototype production and small series production. A particular advantage of this process is its speed and flexibility: by focusing and changing the light output, cuts can be made at different levels of the material, such as markings or engravings, kiss-cut cuts or cuts that completely sever the material.
Since no tools are required for laser cutting flat gaskets, there is no need to invest in tool costs. All that is required is CAD data in DXF or DWG format for the desired product. Contours can also be corrected with little effort based on CAD data , which is particularly advantageous in development processes.
Depending on the homogeneity of the material, the cutting pattern remains consistently high - no further processing of the cutting edges is required. Laser cutting enables parts to be produced that:
- have a low material thickness
- consist of materials that are available as rolls or in the form of individual sheets
- can be produced in a cutting area of approx. 300 mm x 300 mm.
The delivery forms of the flat gaskets are diverse and range from parts lined up on a strip to sheets and marked or engraved parts. Perforations or bending lines can also be created on the punched gaskets.
When it comes to the manufacturability of laser-cut parts, it is important to note that the cutting result depends on the material properties, thickness and density - the laser cut is a burn-off . Depending on the material, this can result in traces of soot on the finished part. Certain raw materials such as PTFE or PVC are not suitable for laser cutting, as toxic substances or gases can be produced when the cut edge burns off, or, as with metallic materials, significantly higher light beam energies are required to create a cut.
Do you have any questions about our products?
Whether O-rings, seals, moulded parts or materials - in the FAQ section you will find answers and lots of further information about the KREMER product range.