An interesting design innovation at K 2010 is an electrically conductive plastic compound from A. Schulman being used by a Finnish lighting manufacturer. Copper and tin are loaded at a very high level (60 and 25 percent respectively) in nylon 6. The tin acts like a solder connecting the copper fibers. “The conductivity of the compound is 1,000 times better than the next most conductive plastic compound available (plastic loaded with steel fibers),” says Thilo Stier, innovation manager for A. Schulman. The first production part is a light made by Hella.
The production process for the light is a great story. First, the ABS plate and the PMMA (acrylic) reflector are injection molded in a three-component process. The electrical resistor, diodes, LED and contact pins for the plug are inserted and connected with the new conductive compound, which is called Schulatec TinCo 50. The ABS-coated reflector is then mounted to ensure watertight encapsulation.
Stier says the material is good for housings and lighting applications.
Airbus Defence and Space has 3D printed titanium brackets for communications satellites. The redesigned, one-piece 3D-printed brackets have better thermal resistance than conventionally manufactured parts, can be produced faster, cost 20% less, and save about 1 kg of weight per satellite.
At IMTS last week, Stratasys introduced two new multi-materials PolyJet 3D printers, plus a new UV-resistant material for its FDM production 3D printers. They can be used in making jigs and fixtures, as well as prototypes and small runs of production parts.
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