3D printing of spare parts, comparison of FDM and SLS processes

Additive manufacturing or generative manufacturing processes, also known colloquially as 3D printing, offer many possibilities for creating prototypes for a wide range of applications.

With regard to youngtimer and oldtimer spare parts, it opens up new possibilities for us in terms of the production of small quantities. This is particularly interesting for small spare parts, such as gear wheels, plastic holders or interior spare parts.

We use the FDM process (Fused Deposition Modelling) for spare parts outside the visible area. We produce plastic holders or gear wheels in a very short time and highly efficiently. This process is carried out by applying layers of special, torsion-resistant and heat-resistant plastic with a resolution of 0.09mm per applied layer. The print head is heated and causes the plastic to melt, so that the individual layers fuse and a new spare part is created. An example is the gear wheel for the seat belt sensor of the Mercedes Benz seat belt retractor. Used in the models w124 as well as W126 in coupe and convertible. The production of a gear wheel in solid material, i.e. 100% filled material structure, takes approx. 60 minutes with a material weight of 3 grams.

We use the SLS process (selective laser sintering) for spare parts in the visible area, especially for a plastic knob for the sunroof crank of the BMW 3 Series e30. In this process, the component is manufactured by a layer construction process using laser technology. The spare part is manufactured from a powdery starting material (plastic e.g. PA12). The advantage of this technology is that even undercuts of 3-dimensional structures are no problem. With this process we achieve very good surface properties. These can be further improved by surface treatment such as barrel finishing or vibratory grinding, resulting in a very nice “finish”. The thermal resistance is given at a melting point of 170 degrees Celsius (PA12).

Another example from our production is the plastic holder or plastic clip for the sun visor of the Porsche 911 series 964.

Additive manufacturing or generative manufacturing processes, also known colloquially as 3D printing, offer many possibilities for creating prototypes for a wide range of applications.

With regard to youngtimer and oldtimer spare parts, it opens up new possibilities for us in terms of the production of small quantities. This is particularly interesting for small spare parts, such as gear wheels, plastic holders or interior spare parts.

We use the FDM (Fused Deposition Modelling) process for spare parts outside the visible range. We reproduce plastic brackets or gear wheels in the shortest possible time and highly efficiently. This process is carried out by applying layers of special, torsion-resistant and heat-resistant plastic with a resolution of 0.09mm per applied layer. The print head is heated and causes the plastic to melt, so that the individual layers fuse and a new spare part is created. An example is the gear wheel for the seat belt sensor of the Mercedes Benz seat belt retractor. Used in the models w124 as well as W126 in coupe and convertible. The production of a gear wheel in solid material, i.e. 100% filled material structure, takes approx. 60 minutes with a material weight of 3 grams.

Spare parts in the visible area especially for a plastic knob for the sliding roof crank of the BMW 3 series e30 we use the SLS process (selective laser sintering). In this process, the component is manufactured by a layer construction process using laser technology. The spare part is manufactured from a powdery starting material (plastic e.g. PA12). The advantage of this technology is that even undercuts of 3-dimensional structures are no problem. With this process we achieve very good surface properties. These can be further improved by surface treatment such as barrel finishing or vibratory grinding.

Another example from our production is the plastic holder or plastic clip for the sun visor of the Porsche 911 series 964.

Please also visit our other articles on the subject of 3D printing and reconstruction for vintage and classic cars.

Are you looking for specific spare parts? Then send us an enquiry via our spare parts form!