Prototype of an insulator made with a 3D printer.
Electric vehicle motors commonly utilize injection-molded PPS resin, and during prototyping, the methods were limited to injection molding and machining. In this context, a 3D printer-compatible PPS resin was developed, which possesses heat resistance and electrical properties equivalent to those of existing PPS resins used in traditional methods, making it suitable for pre-mold production purposes.
■ Processing Method
3D Printing: Powder Bed Fusion
■ Material
PPS GF (Glass Fiber Reinforced Grade)
■ Size
168 x 116 x 15 (mm)
【Concerns】
- Existing methods take over a month for delivery.
【Requests】
- Desire to obtain prototypes within 1 to 2 weeks.
- Want to confirm functionality equivalent to actual products (injection molded) (heat resistance, electrical properties, low water absorption).
- Aim to prevent damage or breakage of wire materials.
【Proposal】
We proposed a method using 3D printer-compatible PPS resin for functional evaluation prototypes, assessing electrical properties in an environment of 120 to 150°C, and were able to conduct evaluations equivalent to conventional products (injection molded). The cost was reduced to one-tenth, and the delivery time was shortened to one week, achieving significant cost savings and lead time reduction.