High-precision and durable gear from 3D printing with up to five times longer service life

igus launches iglidur i4000, the world's first 3D printing resin for wear-resistant gears

Gears are at the heart of many mechanical systems. They drive machines, make precise movements in robots possible and are indispensable in gearboxes and vending machines. Customised and durable gears are increasingly in demand. For this reason, igus has now developed a new 3D printing resin for the DLP process with iglidur i4000. The innovative material has been specifically designed for the special requirements of gears. Compared to conventional 3D printing resins, it offers a 13 times higher elongation at break and a five times longer service life.

Three years ago, plastics specialist igus launched its first resin, iglidur i3000. It is characterised by its high resolution and precision in the DLP process for producing wear-resistant parts. "Over the last two years, we have noticed an increasing demand for lubrication-free gears in a wide variety of shapes and sizes. Resins are a very good option as the process allows for component quality similar to that of injection moulding," explains Jonas Burk, Head of Business Unit Additive Manufacturing at igus GmbH. This is why igus has pushed ahead with its research into synthetic resins and developed iglidur i4000, a material that is particularly suitable for manufacturing wear-resistant and precise gears. "Especially during pre-development, when it comes to proof of concept or proof of principle, the resin is ideal for gear prototypes because production via DLP is fast and cost-effective. Customisations can be made within a very short time," says Burk. The material is suitable for DLP, SLA and LCD printers.

Service life increased by a factor of five

In addition to the mechanical specifications, conventional resins are often not designed for wear and load in gear applications. "Our resin has been specially designed to meet the requirements regarding performance, flexibility and stability," explains Burk. The iglidur i4000 resin was developed in close cooperation with customers and is characterised by high wear resistance and elongation at break, which is important as gears are exposed to a permanent load during movement. Tests in the igus 5,500m2 laboratory show that iglidur i4000 offers a five-fold longer service life and 13-fold higher elongation at break compared to i3000 and high-toughness resins. The self-lubricating specifications of the material also allows users to dispense with grease or oil in the application, which makes the gear free from lubrication and maintenance. The first customers are already using the new resin.