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[Automotive Industry Case Study] Prototyping Evaluation of PPS with 3D Printer

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.