Knaus Tabbert AG is a leading manufacturer of recreational vehicles. The company’s innovative designs and powerful drive systems for motor homes, caravans, and panel trucks allow for safe, comfortable, and sustainable travel.
At its German headquarters in Jandelsbrunn, Bavaria, Knaus Tabbert utilizes its comprehensive experience and know-how to continuously improve the materials and designs of its vehicles as well as new manufacturing technologies such as additive manufacturing.
Seeking faster and less expensive post processing for its 3D printed prototypes, Knaus Tabbert turned to AM Solutions, a brand of The Rosler Group, to find a better way.
From prototyping to production, Knaus Tabbert needed de-powdering and cleaning operations for additively manufactured work pieces.
“On the one hand, we are using 3D printing technology for creating prototypes. On the other hand, we are also utilizing additive manufacturing for producing standard components in volume such as the bracket for an alarm system or the hinge mechanism for the swing-out shower stall,” said Mario Meszaros, Knaus Tabbert Development Engineer.
Growing utilization of additive manufacturing for volume production of plastic components has increased the demand for cost-efficiency and high-quality surface finishes. That’s why AM Solutions, a brand of the Rosler Group, has further expanded its product portfolio with the development of a new media type for post processing of plastic components.
Designed specifically for work pieces printed with MJF and SLS powder-bed-based technology, AM Solutions’ new media permits the safe, cost-efficient finishing of 3D printed components with different shapes and sizes in one single process step and with absolutely repeatable results. This eliminates the time-consuming and costly media changes for different processing stages.
In combination with an understanding of respective printing processes, the new media mix generates a perfect, finely structured, and highly homogeneous surface finish.
While choosing the right implant material is of utmost importance, as discussed in our previous Orthopedic Implant Series post, the significance of optimum surface treatment throughout the entire implant manufacturing process cannot be overstated. This relates not only to the right surface finish, but also total compliance with the specified tight dimensional tolerances.
The functionality of an orthopedic implant is determined by the perfect match between the various implant components. This depends, to a large extent, on the surface treatment procedure(s).
Critical aerospace components require first-class surface treatment. From engines, fuselage, wings, and landing gear to seats, gears, propellers, blades, fasteners and tanks for fuel, water, and waste, Rosler has industry experience and expertise.
While mass finishing and shot blasting methods are equally useful to manufacturers of new components and in the overhaul and repair of existing components, shot peening – a particular type of shot blasting – is especially advantageous for aerospace work pieces thanks to its ability to provide surface finishing and create internal compressive stress for improved component life.
Shot Blasting Capabilities
Rosler’s shot blasting technology meets the strict surface finishing requirements predicated by tight tolerances for safety and longevity. This impact-based process propels small metal or mineral pellets onto a work surface at speeds of 200-800 feet per second.
Desired finishes including cleaning, texturing, removal of or preparation for coating, and peening can be pinpointed to specific areas of a given work piece as well as the entirety of large, structural components.
While choosing the right implant material is of utmost importance, as discussed in our previous Joint Reconstruction Series post, the significance of optimum surface treatment throughout the entire implant manufacturing process cannot be overstated.
This relates not only to the right surface finish
– be it a high-gloss polish for low friction, a textured surface for easy
osseointegration, or as preparation for subsequent coating, rounded edges, etc.
– but also total compliance with the specified tight dimensional tolerances. The
success of a joint implant is determined by the perfect match between the
various implant components. This depends, to a large extent, on the surface
Advanced composite and metal additive manufacturing components require final surface finishing.
Whenever the surface of aerospace, automotive, creative, dental, industrial tooling, medical and moulding tools are produced with additive manufacturing the surface requires to be improved.
Additive manufacturing, the creation of 3-D solid objects by using a series of layered materials, allows the production of complex individual components from various materials such as plastic, nickel alloys, titanium, stainless steel and precious metals.
It permits the creation of shapes and geometries which are not possible with any other production method. However, the surface finish of parts created with additive manufacturing frequently requires final finishing.
The adaptation to particular work piece shapes and surface requirements can be achieved by the development of tailor-made finishing solutions.
Equipment and process methods for either the intensive or very gentle surface smoothing of such components are available according to their component substrate and design geometry.
Surf-Finisher – a new standard for automated precision surface finishing
Surf Finishing is a new surface finishing technology that can be incorporated in an automated system combining; loading, handling, processing and even inspection all in one which can give an added benefit of retaining traceability on parts.
Surf finishing is a fully automatic, dry and/or wet processing method with; extremely short cycle times, high process stability, repeatability and can provide finishing of precisely targeted surface areas for deburring, surface grinding, smoothing and polishing of delicate, high-value components with complex geometries.
Mass finishing machines come in different shapes, sizes and styles; from vibratory bowls and troughs, high energy centrifugal disk machines to drag finishing. Machines can often be chosen in batch and continuous flow versions and as such their application range is as wide as it is varied. below are just some of the possible applications: