Connection technology meets 3D printing
Flexible connector solutions from the printer
3D printing is becoming increasingly important in series production and enables flexible, fast and precise production processes. The example of the Lapp Group shows how additive processes help to efficiently implement customer requirements and realize innovative connector solutions.
For a long time, 3D printing was primarily at home in product development - ideal for the rapid implementation of prototypes, test housings or design studies. However, with increasing material diversity and ever more powerful printers, the technology began to make the leap into series production. Today, industries from automotive to medical technology use additive processes for complex components that would not be so easy to produce using conventional methods. "In principle, 3D printing allows decentralized, on-demand production directly on site - without long delivery times or tooling costs, and that can be a real competitive advantage, especially in times of geopolitical uncertainty and volatile markets," explains Dr Philipp Baron, Research Engineer Advanced Technology at the Lapp Group. The cable and connection technology specialist is relying more and more on the printing process, which has so far been used less in the cable sector, but all the more in the connector sector.
Implement customer requirements faster and more cost-efficiently
In recent years, Lapp has invested in this area, also known under the brand name Epic: new development processes, new suppliers, better cooperation with the interfaces and also in machines and expertise in the field of additive manufacturing. The 3D printing process allows customer requirements to be implemented faster and more cost-efficiently. For some time now, the Stuttgart site has therefore had a system that can be used for the production of both prototypes and series components. With Dr. Philipp Baron, responsible for the 3D printing process in the pre-development department, and Stevens Sehic, team leader for connector development, the necessary expert knowledge is available alongside the printing machines.
"We use 3D printing to produce prototypes on an ongoing basis, which we use internally to implement ideas and design drafts in the shortest possible time," explains Dr. Baron. "This allows us to test many parts efficiently and conduct research with them or, for example, check their pluggability." The process also makes it easy to take into account special requests from customers or test whether a component fits well in the hand. If a newly developed connector then passes all the tests that can be carried out on the 3D-printed prototype, all the innovations can be integrated into series production.
Quick solution, satisfied customer
For example, one customer told Lapp about a problem with moisture in the control cabinets they produce. Even built-in dehumidification elements did not help with the humidity condensing on the inside walls of the enclosures due to temperature differences. Sooner or later, the moisture accumulated inside the enclosure and then ran towards the connectors inserted through the floor. The consequence: impending malfunctions and possible short circuits. The customer previously remedied the situation with a laser-cut stainless steel component that shielded the plug connector from the liquid - a complex and expensive solution that did not offer one hundred percent protection.
A challenge for Lapp: a simple solution that keeps moisture away from the connectors and is compatible with standard components. Lapp's team of experts quickly drew up a concept and carried out the first printing tests. Just three days later, the first production-ready prototypes were ready. In series production, the solution is technically feasible with a UL-certified material.
Numerous connectors and components have already been created for Lapp's Epic series in this way and with the help of the additive manufacturing process. These include, for example, the Epic H-B 16, which is characterized by its improved, rectangular connector design, the Epic H-Q TS M25, an in-house development that features a new type of housing with an internal thread for cable glands and a compact design, or the Epic MCS-HC 2, a module insert for a modular connector system, and the Epic Power M23, a robust contact carrier made of UL-certified material with a delicate structure.
The key to the challenges of the future
The examples show: Additive manufacturing is actively driving change in industrial development and production processes. Wherever customized solutions are required in a short time, 3D printing shows its greatest strengths: Flexibility, speed and precision. However, progress also brings with it new challenges - such as the standardization of materials, certification of processes or integration into existing production systems. Despite these hurdles, development is progressing at a rapid pace. The potential is growing, as are the possible applications at Lapp. For the Stuttgart-based specialist for connection solutions, additive manufacturing is therefore not only the answer to current requirements, but also a key to mastering future challenges innovatively.
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