Protiq produces prototypes and series components from Zamak 5 overnight on 3D printers. © Protiq

By using additive manufacturing, functional prototypes can now be produced from Zamak 5 with the properties of the subsequent series component at an early stage of product development. No costly tools are required for this, as production takes place directly from the 3D CAD data. The additively manufactured workpieces can be electroplated as usual, for example to achieve an elegant, high-gloss chrome look. The typically very rough component surface must first be polished for this. In contrast to zinc die casting, which only pays off from very large quantities, 3D printing enables the economical production of individual pieces and small series, so-called "low runners". Thanks to additive manufacturing, product development, the start of series production and the supply of spare parts also pay off for small quantities.

Free definition of geometry

In addition to the significant time and cost benefits, 3D printing of zinc components also offers new potential. In contrast to zinc die casting, almost any conceivable geometry can be created thanks to the layered structure of the components. Restrictions due to material accumulations, separation planes or ejectors no longer need to be taken into account. In particular, small and delicate components with new functions can be brought to market within a day or produced in series using selective laser melting. Another interesting feature is the ability to produce any number of different geometries simultaneously on one system.

The surface finishing of 3D-printed zinc components enables them to be used in visible areas. © Protiq

Print on demand" enables the direct, tool-free production of products immediately after the order is received. In this way, the customer saves on storage costs and logistics costs are also reduced to a minimum. Such business models have already become established in the paper printing sector. The customer orders their book online and automatically triggers the printing process. The product is then sent to them the next day, hot off the press. The new additive manufacturing technology for zinc components is now also opening up this new business area for the production of industrial components. If the advantage of immediate, fast production is also combined with the new freedom of geometry, there is also the opportunity to produce customized components in series. "Complexity for free" is the keyword. With additive manufacturing technology, product variants or labeling, for example, can be freely defined.

Immediate feedback on manufacturability and costs

To this end, Protiq's range of services already includes several online configurators. Without any specific design expertise, any user can design their individual product online and free of charge within a few minutes and initiate production directly as "print on demand". Thanks to Protiq's standardized and digitalized processes, Zamak 5 components are ready for delivery within just a few working days.

Another special feature is the "instant pricing" for zinc components on the web platform. The manufacturability of the component geometry provided by the customer is automatically checked and a price for production is generated within seconds. This means that the product developer does not have to wait weeks for the information and can carry out meaningful tests much earlier. In addition, any change to the 3D model can be quickly and cost-effectively applied to a new prototype, resulting in greater flexibility and considerable added value in product development.

Protiq therefore offers the ideal conditions for producing small and medium-sized series to the highest quality standards in addition to prototypes. The high quality standards are guaranteed thanks to certification in accordance with DIN ISO 9001 and as an additive manufacturer in accordance with the PPP 11001:2018 standards by TÜV Süd. Dr.-Ing. Johannes Lohn, Head of Development, Protiq

Protiq, http://www.protiq.com