Camper van expansion with igus® linear technology

Custom-Bus Camping Vans based at Langenhagen, Germany customises camper vans, RVs, motor homes and can now turn Volkswagen T6 vans into offices.

One of their customer built models contains a kitchen box. The handle-free system has sink, stove extractor, freezer compartment and storage space and weighs about 35 kg. The ‘Business’ version replaces the kitchen with an office system that weighs around 15 kg and contains everything a mobile office needs. However their is a special feature: each box moves via a sliding unit integrated in the furniture and removed easily.

In the search for suitable sliding elements, Craig Kammeyer assessed many linear systems. “They have to be lubricated,” explains Craig Kammeyer. “Over time dirt will stick to the lubricant, which would impair the smoothness of the sliding system. In addition, these systems are expensive and do not fit well into the filigree construction of the interior. igus® drylin® W linear systems solve all these problems.”

Between the rail, which is made of hard anodised aluminium, and the carriage there is a bearing surface of abrasion-resistant iglidur® plastic, which provides excellent results in terms of friction and wear. Solid dry lubricants are incorporated within in the material. This means that the bearings provide the long-term, maintenance-free dry operation and meets the required service life of at least 15 years.

From high load to high temperature: individual parts from 50 iglidur® materials available within 2-5 days

With custom-made 3D-printed injection moulding tools, igus® offers designers a new possibility to produce self-lubricating and maintenance-free parts and small batches. Engineers can now choose from the entire range of 50 iglidur® high-performance plastics, including specialists for high load, food contact, underwater or high temperature applications, with delivery within 5 days of order.

Injection-moulded, 3D-printed or machined from bar stock – the motion plastics specialist igus® offers engineers a wide range of possibilities to obtain their self-lubricating parts, such as gears or plain bearings quickly and cost-effectively. igus® also offers the possibility to solve difficult technical challenges quickly by means of a 3D-printed mould – and now with all tried and tested iglidur® materials.

“Since the production of injection moulds made of steel is comparatively expensive, takes longer and is only feasible in the production of large quantities, special tribo solutions can be produced with a printed mould within 2 to 5 days with up to 80 percent cost savings in production and further, even small quantities can be produced,” says Robert Dumayne, dry-tech® director, igus. “A new process for the production of printed injection moulding tools now allows igus to make even more precise and long-lasting products.”

The material selection of the moulded part determines the material and the manufacturing process of the printed mould. “From an availability of 50 tribologically optimised and online configurable iglidur® materials, designers are free to choose the right material for their special part,” continues Dumayne. “For example, iglidur® G is an all-rounder, whereas iglidur® X is for long-term application temperatures of up to 250°C.”

Depending on the material chosen for injection moulding, the mould is either SLA or SLS printed and then used immediately in the injection-moulding machine. Thus, parts are ready for shipment within a few days. The material structure of the printed injection mould ensures that it can withstand the high temperatures during injection moulding, which means that one mould can produce prototypes and small batches up to 500 pieces cost-effectively and quickly.

“The production of special tribo-parts by means of printed injection moulding tools is particularly advantageous if the desired material cannot be processed in the 3D printer or when the parts are used for a test that is intended to simulate as close as possible conditions for a later mass production,” explains Dumayne. “We have moulded over 2,000 moving parts already, using printed injection moulding tools.”

For more information, please contact igus on www.igus.co.uk/3dprintedmould or call igus directly on 01604 677240.

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