Usage of Flexfill TPU 98A,
ASA Extrafill, CPE HG100 and HIPS
in company KES
Company KES kabelové a elektrické systémy spol. s r.o. (Cable and Electrical Systems) was founded in 1992 and is based in Vratimov in the Ostrava district. Wiring harnesses for the automotive and electrotechnical industries are manufactured on about 10,200 m² of manufacturing premises. KES produces over 600 products, mainly for the automotive industry. Its products are a part of successful automotive brands such as Audi, Bentley, BMW, DAF, Daimler, Ferrari, Ford, Lamborghini, Land Rover, MAN, Nissan, Opel, Rolls-Royce, Seat, Škoda, Volvo, VW, etc.
This case study is focused not only on time or cost savings but also on printing gadgets that protect employees from injury. Mr. Jošek, a designer in the company, answered our questions and details explained what the company uses AM for.
WHAT IS THE MAIN REASON YOU HAVE STARTED 3D PRINTING?
All of the printed parts (prototypes or functional pieces) are made mainly for financial savings. We do not have our own machine tools and the designed parts are manufactured externally – 3D printing is also time-saving. Functional parts are implemented into the production process as soon as possible. Prototypes are tested first, the functionality must be verified and then we order external production, e.g. from stainless steel.
WHAT ARE THE PRINTED OBJECTS USED FOR?
PREPARATIONS FOR TEXTILE TAPE BANDAGE OF WIRES
The device is used for machine bandaging of wires at the exact distance from the connector. The product in the picture is intended for a total of 3 bandages at different distances. The feed on the linear guide is fixed by pneumatic rollers. The connector is inserted and moved manually. The machine was supplied by the Kabatec company, the product is designed by KES.
TOOL PROTECTOR
The main function of this printed part is prevention of press head hitting an anvil when storing or manipulating. At the same time, the tool protector protects on operator from finger injuries when transferring the tool from the warehouse to the workplace (there was a risk of pinched fingers between the press head and the anvil). Another function of this part is to indicate the status of the tool.
CONNECTOR PRINTING TOOL
According to the customers’ requests such as volume number, revision, date, and time of production, this information is printed on the connector by inkjet printing. The worker inserts the connector into the holder, The connector is locked with pneumatic rollers and printing starts. The print head is pneumatically driven and is attached to a linear guide. The connector holder, the construction for moving of the printed head, and the electronics covers are 3D printed.
TEST MODULE
Test modules are used to check the quality and functionality of the bundle (electrical test, tightness test, detection of arrest, test by pushing the contact out of the connector – the so-called push-back test – when the contact must withstand a certain force of extrusion), or it performs actions that are part of the assembly (e.g. closing the locking of connectors, marking off the OK piece, etc.). The whole bundle is tested on a board on which several modules are mounted. Each module is designed for some type of connector or performs a certain function. The module in the picture is intended for a push-back test. The connector is inserted into the module, it is locked by pneumatic rollers. Push-back probes arrive pneumatically and if the needles are closed, the result is OK. After testing the entire bundle, the components are released – unlocked.
HOW WAS PRINTING WITH FILLAMENTUM MATERIALS? WHAT MATERIALS DID YOU USE?
We print in CPE HG100 (Black soul and Ghost White), ASA Extrafill (Natural and Traffic White), Flexfill TPU 98A (Luminous Green, Signal Yellow, and Signal Red), and HIPS (Natural). The instructions for printing each material are a great help. Testing new filaments is easier now. The filament has never been bent or broken; the end of the filament always gets out of the spool without any problems (but to be sure we shorten it as much as possible). Both, the CPE and Flexfill materials, have excellent cohesion between the layers, Flexfill adheres very well to the bed, CPE is excellent for “bridging”. One has to find a way to print ASA and HIPS materials. Once they fine-tune the printing process, they are printed great. We have a glass mat, for low temperatures we use 3Dlac and for high temperatures Dimafix.
WHAT DO YOU LIKE MOST ABOUT OUR BRAND? WHY DID YOU CHOOSE FILLAMENTUM?
I like reading case studies on the website. It is a good inspiration on how to use 3D printing and the materials, for example, an article about a pneumatic screwdriver – as soon as there is room for printing, we will definitely try to print the pneumatic motor. Because our 3D printer, filament diameter of 2.85 mm is required, we have a limited selection of manufacturers. Fillamentum has a wide range of materials and colors, even in a less common diameter of 2.85 mm. Other criteria were price and availability.
