3D Printed Sensor Created by Fraunhofer and ARBURG

IMTS

Share this Article

One of the many Holy Grails of 3D printing is the ability to 3D print fully functional items in a single build process. Companies like Inkbit and Sakuu are after just such a goal with their multi-material processes. However, it may not require completely new 3D printing methods, such as theirs, to produce such functional objects as electronic devices. A research team from the Centre for Additive Production at the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) has demonstrated the ability to manufacture a sensor using a single-material deposition technique from ARBURG.

The team at Fraunhofer IPA pursued the production of an inductive proximity sensor directly within its casing. These cylindrical devices typically consist of a coil, circuit board, and plug within a metal shell. They can be used to measure the distance of a metal object in industrial manufacturing and other applications. However, due to the standard, mass produced shape of the sensors, they can’t always fit ideally into a given environment.

The ability to 3D print complex, multi-material goods has a range of benefits. In addition to reducing labor steps, additive manufacturing (AM) of such items could enable the mass customization of electronics or complex geometries that could improve the performance of the device. For instance, by integrating a smartphone battery and antenna directly into its polymer casing, the phone could be made smaller and lighter weight, while increasing energy density or communication range.

Freeformers in sizes 200-3X and 300-3X process plastic granulates, as also used in injection molding. Image courtesy of Arburg.

Freeformers in sizes 200-3X and 300-3X process plastic granulates, as also used in injection molding. Image courtesy of Arburg.

In the case of a proximity sensor, Fraunhofer IPA suggested that it could be possible to integrate one directly into a robotic gripper to make fore more intelligence handling of items in a production line. To demonstrate this possibility, the Fraunhofer team worked with a Freeformer 3D printer from ARBURG, which uses a proprietary method to melt plastic granules and deposit them onto a print bed, as well as automation firm Balluff GmbH.

It was necessary for the researchers to use a plastic with high dielectric strength and flame-retardant properties, leading them to plastic polybutylene terephthalate (PBT). While PBT is a standard injection molding material for electronic casings, it is not used in 3D printing. Here, ARBURG was able to demonstrate one of the strengths of the Freeformer, which processes injection molding pellets over plastic filament and, thus, has access to a much broader range of materials.

Fraunhofer IPA's 3D printed sensor, including coil, circuit board, and plug within plastic casing. Image courtesy of Fraunhofer IPA.

Fraunhofer IPA’s 3D printed sensor, including coil, circuit board, and plug within plastic casing. Image courtesy of Fraunhofer IPA.

The team 3D printed the part, leaving openings in which outside components could be integrated during the fabrication process. The machine was programmed to stop where necessary so that the coil, circuit board, and plug could be inserted into the printed part. Meanwhile, a dispenser applied the silver conductor tracks within the casing. Once these steps were complete, the Freeformer printed over the openings.

Altogether, Fraunhofer created 30 customized sensors and ran them in standard operating environments, showcasing their ability to withstand changes in temperatures and vibrations. The devices were additionally waterproof and could pass an electrical insulation test. The project, dubbed “Electronic Function Integration in Additively Manufactured Components”, lasted 18 months and the team is now working with ARBURG to explore further uses for conductive plastics.

Share this Article


Recent News

Liquid Metal 3D Printing Sector Emerges with Fluent Metal’s $5.5M Investment

3DPOD Episode 191: Amy Alexander, 3D Printing at the Mayo Clinic



Categories

3D Design

3D Printed Art

3D Printed Food

3D Printed Guns


You May Also Like

3DPOD Episode 190: Generative Design for 3D Printing with Novineer CEO Ali Tamijani

Ali Tamijani, a professor in the Department of Aerospace Engineering at Embry-Riddle Aeronautical University, has an extensive background in composites, tool pathing, and the development of functional 3D printed parts,...

Featured

3DPOD Episode 189: AMUG President Shannon VanDeren

Shannon VanDeren is a consultant in the 3D printing industry, focusing on implementation and integration for her company, Layered Manufacturing and Consulting. For nearly ten years, she has been involved...

3DPOD Episode 188: Clare Difazio of E3D – Growing the Industry, and Growing With the Industry

Clare DiFazio’s journey into the 3D printing industry was serendipitous, yet her involvement at critical moments has significantly influenced the sector. Her position as Head of Marketing & Product Strategy...

Featured

Printing Money Episode 15: 3D Printing Markets & Deals, with AM Research and AMPOWER

Printing Money returns with Episode 15! This month, NewCap Partners‘ Danny Piper is joined by Scott Dunham, Executive Vice President of Research at Additive Manufacturing (AM) Research, and Matthias Schmidt-Lehr,...