Certified Additive Manufacturing at 3Faktur

Part
Orientation

Part orientation has a decisive influence on dimensional accuracy and surface quality. Each component is individually analyzed and oriented by our experienced experts to ensure the best possible balance between surface quality and dimensional accuracy in all dimensions.

Manufacturing-
Analysis

All parts are subjected to a basic analysis to determine whether they can be manufactured or whether potential problems may exist. For example, the component is examined with regard to wall thicknesses or potentially problematic geometries, such as narrow internal channels, geometries at risk of warpage or similar.

Customized Production Parameters

Individual production parameters are defined for each 3D model to achieve the best possible result. For example, the distance to other components and the position in the build chamber are defined individually.

Customized Pathways

Every part is different, every project has its own specific requirements. An individual process flow (‘pathway’) is defined for each order, which, in addition to basic processing steps, also contains geometry-specific instructions for the workers.

Nesting

Once all parameters have been defined, the next step is “nesting”. In this process, all parts of a production cycle (typically 50 – 300 components) are nested in such a way that an optimal ‘job’ is created. The aim here is to achieve as balanced a heat profile as possible. The more even the heat distribution in the printer, the better the dimensional accuracy, surface finish and mechanical properties.
The ‘art’ is to prepare the part for a job as optimally as possible and to select the number and type of components. This requires a great deal of intuition and, above all, experience.

Defined Production Cycles for Batch Production

If parts are produced in hundreds or thousands and called off regularly, individual production profiles can be created. The quality achieved is intensively evaluated after the first run and, if necessary, the parameters are further optimized. The aim here is to ensure the best possible replicability and quality. In addition to general production parameters, this also includes ensuring that series parts are always produced on an identical hardware combination.

Quality-Oriented Print Parameters

Printing is carried out in “Balanced Mode” (layer thickness for polyamide 12: 80 µm). The mode offers an optimum balance of mechanical load-bearing capacity, surface quality and dimensional accuracy. An individual parameter set is defined for each production cycle, which is based on the experience of thousands of cycles.

Slow Cooling Process

During 3D printing, the installation space in the printer heats up very strongly. We set the cooling phase to be very long (at least 2 days) and refrain from accelerating the cooling phase (“fast cooling”), since an extended cooling time significantly improves dimensional stability, mechanical properties and surface quality.

Controlled Production Environment

The thermal processing of polymers requires high demands on the production environment. Our production facilities are fully air-conditioned so that temperature and humidity are always kept constant to ensure maximum replicability in series production.

Industrial Manufacturing Technology

Our machinery includes state-of-the-art production equipment, which is maintained and calibrated before each production cycle. High replicability is the measure of all things for us, which is why wear parts are also usually renewed before they expire, in order to avoid possible quality effects at the end of their service life.

High
Capacity

Due to our high level of specialization, we have sufficient capacity in both production technology and post-procesing to handle even large quantities. In multi-shift and weekend operation, we also absorb utilization peaks and were thus able to achieve an “on time delivery” rate of over 99% in 2021.

High Quality
Raw Materials

We use only certified, high-quality raw materials, for production and in post-processing. Each new batch of material is checked – and also before each production cycle, we check that the raw material meets our high quality standards.

Replicable
Processes

As a specialized supplier, we concentrate all resources on one manufacturing process. Thousands of components pass through this process every week under constant and optimized conditions. Each cycle is logged and controlled and continuously improved.

Optimized Machinery

In order to optimize the quality, replicability and efficiency of the manufacturing processes, we also rely on special machines designed and manufactured for our requirements, which help us to make our production processes even better.

Large
Experience

As one of the first providers of Multi Jet Fusion technology in Germany, we can build on a wealth of experience. Our processes are documented, controlled and stable and reliable even during peak loads or unforeseen events (e.g. machine failure). That doesn’t mean we can’t get even better: we focus on continuous improvement to exceed your high standards every day.

Systematic
Quality Assurance

Quality checks are performed at all production steps in our manufacturing. Various control and measurement steps are carried out in the final quality control. This includes, among other things, individually agreed measurement protocols, various spot checks, and intensive testing of accompanying production samples.

Modern
Testing Technology

Additive manufacturing allows the production of very complex geometries. We can test most geometries in our QM laboratory with modern measuring technologysuch microscopies or laser based scanners.

Individual
Test Plans

In additive series production, we often use individual, i.e. part-specific, measurement protocols. Specific measuring points essential for the function of the components are tested or functional tests are carried out. In addition to the type of tests, the individually agreed number of samples, up to 100%, is also determined.