The vacuum process enables fast, efficient and cost-effective production of desired structural and molded parts. In addition, two different materials (hard and soft) can be combined during production. Inserts (magnets, threads, inserts, etc.) can also be integrated into the component.
The term “food grade” refers to materials that are harmless to health due to their physical composition. They have no odor or taste effect on food. They give rise to new applications for prototypes and small-series production in the household appliance industry.
For many of our 3D-printing materials we either have material samples in stock or can produce them. Material samples are available as tension rods or technology sample boxes. You can order technology sample boxes here. For tension rods, please contact your Sales representative.
A key feature of surface finishing is the ability to give models and prototypes additional functions. For example, the surface can be protected against corrosion, and further enhancements can be made in terms of temperature resistance or durability.
Another advantage is optical refinement and thus the improvement of aesthetic and decorative properties. At 1zu1 we offer the following methods: infiltration, polishing, tumbling, printing, laser marking, vapor deposition/metallization, hot foil stamping and heatset impregnation.
A DXF file (Drawing Interchange File Format) is a file format for data exchange in CAD. This file format DXF file is integrated into the CAD program AutoCAD. This enables and performs data exchange between different types of AutoCAD executions.
The STEP exchange format (Standard for the Exchange of Product model data) is a standard for describing product data. It enables the exchange of three-dimensional graphics and product definitions in heterogeneous computer-aided CAD, CAM and CAE systems.
Parasolid is a modeling kernel for 3D CAD systems, originally developed by the company UGS and acquired by Siemens PLM Software in 2007.
Elastomer materials (PU rubber) are available in various degrees of hardness from 30-90 Shore A. Thermoplastic-like materials are available in degrees of hardness from 45-85 Shore D.
| Shore A | 30 | 40 | 50 | 60 | 70 | 80 | 90 | 95 | ||||
| Shore D | 45 | 55 | 60 | 65 | 70 | 80 |
Polyurethane is the collective chemical term for elastic to hard plastics produced from polyalcohols and polyisocyanates. The curing reaction is a polyaddition. Polyurethanes have many uses, e.g. for the production of household sponges, adhesives, paints and floor coatings. Synthetic textile fibers such as polyurethane are also used in the fashion sector.
The production process takes place in a vacuum or under negative pressure. What is the effect of this vacuum? On the one hand, it ensures bubble-free processing of the material. On the other hand, flow resistance within the mold caused by air pockets is avoided. This means that at 1zu1, we can achieve homogeneous, pore-free material properties.
- From master model to casting mold:
- Casting in vacuum
- For simple components directly via a casting mold in 3D printing or milling technology: For series application 1zu1 recommends 100 to 200 pieces.
- 3D printing of silicones:
- Discharging the material via nozzles or injecting a catalyst into a silicone bath
- Cantilevered components are possible
- Layered structure visible
- Vacuum casting materials: use of original silicone, including food-grade silicone
We have special expertise when it comes to prototypes made from food-grade plastics and silicones. The use of these basic materials, which are approved by the Food and Drug Administration (FDA), makes it easier to obtain FDA approval for the respective part.
We can hand over the necessary documentation for FDA approval to our customers, thereby enabling them to submit the respective FDA application. In this context, the term “food grade” refers to materials which, due to their physical composition, are harmless to health and impart no odor or taste to the food. They give rise to new applications for prototypes and small-series production in the household appliance industry.
For example, we tested the use of a transparent polyurethane material for vacuum casting on behalf of a well-known coffee machine manufacturer. Using food-grade dyes, plastic parts can be produced in virtually any desired color and adapted to meet the strict approval requirements of the American Food and Drug Administration.
Silicone
Flexible parts, such as hoses or seals made of silicone, can also be produced by 1zu1 in any color and in a Shore hardness of between 00 A and 65 A. Food-grade parts can also be produced in a Shore hardness of 00 A, 43 A and 65A.
Rubber
Elastomer materials (PU rubber) are available in various degrees of hardness from 30-90 Shore A. Thermoplastic-like materials are available in degrees of hardness from 45-85 Shore D. Typical areas of application include housings, covers, gaskets, covers for vehicle apparatus construction, foundry models, model and prototype construction, mold tubes, hoses …
- Glass fibers/glass-fiber mats with a weight ratio of up to 20 percent are possible. Instead of higher strength, in most cases this results in increased hardness and dimensional stability and, in some cases, higher thermal stability. However, glass fibers reduce the elongation at break!
- Carbon fiber/carbon fiber mats
- Sand
Polyurethanes (as well as series materials) can of course be reinforced with various additives. The latter often produce different effects compared to their use in injection molding – for example, because the glass fibers are not “directed”.
SHORE hardness, named after Albert Ferdinand Shore, is an indicator used primarily for elastomers and rubber-elastic polymers. It is directly related to the penetration depth and is thus a measure of the material hardness.
3D printing
The fastest and cheapest method for prototype production is to use 3D printing . The starting point is a digital, three-dimensional model of the component that is imported from a CAD or 3D programming system. The data is transferred directly into the component without molds and tools, which saves costs and time. Prototypes can be produced in only a few days (fast availability). Further, decisive advantages of prototyping with 3D printing include the ability to implement changes at short notice, a fast learning curve and arrival at a series solution via a quick succession of iterative steps.
Injection molding with aluminum mold tool
If it is necessary that the production is based on the original material, the injection molding process with aluminum molds is also an option. Plastic injection molding
The chosen material is liquified and injected into a mold under pressure.
Vacuum casting
In addition to these direct, additive processes, subsequent casting processes are also available (on the basis of a 3D-printed master model).
For 1zu1 prototypes, this is plastic vacuum casting with polyurethane casting resins.
Mechanical manufacturing
Another option for the production of prototypes is mechanical manufacturing.
Our turning, milling and lathe-milling machines enable us to produce complex models and components in original materials (e.g., PA6 GF 30, Grivory, etc.) within the usual rapid-prototyping time frames, which range from a few days to several weeks.
Design prototype
A design prototype is used to verify aesthetic and ergonomic features. These prototypes/models fulfil three functions. Firstly, they enable detailed design studies (spatially realistic representation, proportions, aesthetics, haptics, technical functionality). Secondly, they serve as presentation objects for decision-making or clarification of acceptance by customers; and thirdly, they form the basis for generating the 3D data needed for design and production.
Functional prototypes
These are prototypes that already exhibit the important functional properties of a subsequent series-production component. Among other things, the mechanical, electrical, acoustic or thermal functions of individual components are verified.
Geometric prototypes
Dimensionally accurate models used for initial assembly and user trials, or to specify a requirement profile. The main focus here is on checking the form and fit accuracy as well as the tolerances. The material-specific properties are less important.
Concept prototypes
These models are used to illustrate a particular concept or test an idea.
- Applications with a total of up to 50,000 parts in the life cycle of a plastic part
- For very small quantities of very few parts, it makes sense to select 3D printing as a production technology from the outset.
- 3D printing: quantities of up to 1,000 are possible and, depending on the requirements of the component, also useful.
Pre-series
Pre-series are put into circulation for the first time by the customer. Later, these are always replaced by series parts. They are therefore used to validate a series, as final test parts for installation or for final functional tests. This should result in a release for series production with only minor modification.
Series
Components manufactured under this term are put into circulation as series parts by our customers. It is important to note that “series” does not stand for the respective customer understanding of a specific industry. Instead, it is the 1zu1 definition for the type of output that can be provided at 1zu1 as a series part. It is therefore important that the customer's own quality requirements are always discussed and agreed with 1zu1 taking into account what we can offer in the way of quality assurance. Validation of the processes is possible.
1zu1 regularly tests new materials, processes/technologies, equipment etc. If the results meet our requirements, we add them to our portfolio.
We share our latest news with prospective customers via the 1zu1 newsletter. You can sign up for it here.
We also perform R&D and research on new materials for 3D printing and vacuum casting.
We monitor the entire market and continuously test new processes, materials and improvements to existing technologies.
Around five to ten times per year we inform our existing and prospective customers about the latest innovations at 1zu1 Prototypes. We will be happy to provide you with this information – you can sign up for our newsletter here.
The core strength of 1zu1 is prototypes and small series. We advise and support you from the initial idea to the finished product. You can read a few of our success stories in the Customer story section. We would also be delighted to help write your success story. Get in touch with us.