FLEXFILL TPU CASE STUDY
FLEXFILL TPU REDUCES COSTS BY UP TO 99 % IN OP CABLE
Published on June 14 by Martin O.
Company OP Cable, a prominent cable and wire manufacturer based in the Czech town of Prostějov, has found an innovative solution to optimize its production process. By harnessing the power of Flexfill TPU 98A and leveraging 3D printing technology, OP Cable has significantly reduced production time and minimized costs. This breakthrough has positioned the company as a trailblazer in the industry, benefiting its operations and customers alike.
Enhancing Cable Reel Production
The heart of OP Cable’s success lies in its utilization of flexible materials from Fillamentum for the production of their two-turn cable reels. Within these reels, an intricately designed arm guides the cable around the rotation axis, equipped with a total of 21 pulleys for smooth cable movement.
The Challenge of Pulley Wear
Over time, the pulleys undergo wear and tear due to the constant cable movement, typically lasting for approximately 3000-4000 kilometers. As grooves begin to form on the pulleys, various issues such as abrasions or incorrect packing can compromise the shielding tape’s integrity. Traditionally, replacing these pulleys proved to be a costly and time-consuming process for OP Cable.
Revolutionizing After-Market Production
Recognizing the high costs and extended delivery time associated with procuring original pulleys, OP Cable made a strategic decision to explore after-market production alternatives. Although this approach reduced costs, it failed to address the issue of extended delivery times. Consequently, the company sought an innovative solution within its own production capabilities by harnessing the power of 3D printing technology.
Empowering Production with Flexfill TPU
Thanks to the exceptional properties of Flexfill TPU 98A, OP Cable achieved remarkable results in its 3D printing endeavors. This flexible material by Fillamentum provided the perfect solution for producing reliable and durable pulleys that could withstand the demands of cable rotation. With Flexfill TPU’s superior performance, OP Cable successfully integrated more than 3,000 kilometers of cables with 3D-printed spare pulleys, ensuring continuous operation and service excellence.
The Impact: Cost and Time Savings
The implementation of 3D printing technology with Flexfill TPU has brought substantial benefits to OP Cable, both in terms of cost reduction and improved efficiency. A comparison of the production of the original part, after-market production, and 3D printing reveals significant advantages:
| Price (in Euros) | Delivery Time | |
| Original Part | 945 € | 8-10 weeks |
| After-Market Production | 210 € | 5-6 weeks |
| 3D Printing | 10 € | 27 hours |
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