Dynamic 2-Component Parts created using Additive Manufacturing

• Applicants: Dr.-Ing. Benjamin Klie; Professorin Dr.-Ing. Kathrin Ottink
• Subject Area: Engineering Design, Machine Elements, Product Development ; Plastics Engineering
• Term: since 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 447009134

This research application focuses on 2-component parts (2c parts) created using additive manufacturing (AM) processes and the general evidence of their functionality in tribological contacts. In sealing technology in particular, the requirements for materials are very demanding. Typical materials used in sealing contacts are thermoplasts, which show very good frictional behavior. Often, one material is not enough to meet all requirements. Contact pressure has to be high enough and secondary sealing has to be achieved. These factors create the need for an additional material in sealing applications. Often, elastomeric o-rings are used and combined with the thermoplastic component as 2c parts. These 2c parts are manufactured separately in a conventional way and later combined in their application. As innovation, this research project aims for a combined additive manufacturing process for both components. For development of the additive manufacturing process for the thermoplastic component one-stage processes, multi-stage MEAM (Material Extrusion Additive Manufacturing) processes, multi-stage binderjetting-based processes and multi-stage DLP(Digital Light Processing)-based processes are taken into account. The suitability of all these processes will be investigated. The elastomeric component will be produced by the application of an FFF(Fused Filament Fabrication) process. The crosslinking of the elastomer will be achieved using a laser. The produced parts will be tested according to leakage, form, and dimensions. Evidence of functionality as a "rod seal" will be provided. Experiments serve to verify the simultaneously developed simulations.Using the procedure explained above, the potential of additive manufacturing can be used in isolated or remote locations for spare-part production "on demand". The scientific approach is necessary for this topic to qualify the components produced by AM for tribological contacts in general. As a functional example for this qualification, a dynamic seal is used because the requirements in sealing applications are very demanding. If 2c-parts created using AM processes are qualified for dynamic sealing functionality, a lot of other applications with lower or similar requirements can also be considered.In this research application, - Hochschule Emden/Leer (HSEL) and the Deutsches Institut für Kautschuktechnologie (DIK) - work together. HSEL has years of experience in additive manufacturing and knowledge in the field of machine elements and tribology. DIK is specialized in the field of production and the investigation of elastomeric components.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Matthias Graf