Efficient and sustainable joining systems, highly complex extruded parts, engineering as well as feeding and processing systems - with this portfolio, Arnold Umformtechnik is known as a development partner for OEMs and suppliers to the automotive and electrical industries. The company is now entering the field of additive manufacturing. The aim of the activities is to supplement the classic service portfolio with fast and customized 3D printing solutions.

"Additive manufacturing gives me a huge amount of design freedom at sometimes very moderate costs. As no molds or tools have to be made for component production, much shorter delivery times are possible," says Uwe Wolfarth, Senior Director Research, Development and IP at Arnold Umformtechnik. For Wolfarth, this results in two possible solutions for joining technology. Firstly, technical solutions can be developed that can later be used in series production. Secondly, prototypes and smaller series of fasteners can be produced. This significantly shortens development times.

Arnold can finish everything that is produced using additive part manufacturing in-house - such as heat and surface treatments or anti-friction coatings. "Everything that a customer knows from a conventionally manufactured fastener, for example, we can also implement. This also includes the corresponding validation: the processes are also carried out at Arnold in accordance with the existing licenses in a standardized and professional manner," says Wolfarth. In the automotive industry in particular, standard-compliant validation of processes is essential. Another important aspect with regard to additive processes is the safety relevance of the component. "It makes a difference whether I print a screw to fasten a brake caliper or one to attach a trim panel," says Wolfarth.

3D printing complements rapid manufacturing

At Arnold, 3D printing is also set to supplement or precede the existing rapid manufacturing process in future. In this area, initial and pre-series samples that are as close to series production as possible are currently produced using conventional manufacturing technology. With additive manufacturing, functional samples can now be produced in a short space of time. After testing by the customer, the results are then implemented using traditional processes for near-series parts. Arnold Umformtechnik uses the SLM process, i.e. the layer-by-layer application of powder and partial welding with a laser beam.

The process not only offers many possibilities, but also brings with it a variety of challenges. "The most important task is to clearly define the actual function together with the customer. Only then is it a matter of determining the most efficient way to reproduce this function in terms of production technology," says Wolfarth. The end result is often a completely different component in terms of appearance and geometry. Arnold Umformtechnik is pursuing two paths with the use of 3D printing. The process is used as a rapid prototyping tool for fasteners. The technology will also be used for other demanding applications. Wolfarth can imagine applications in the field of mechanical engineering and component production as well as in-house mechanical engineering, for example for automation components: "We recently developed a press-fit technology for inserting and connecting electronic components. The press-fit tools were completely printed for this purpose.