Additive manufacturing

Additive manufacturing is ideally suited for topologically optimized components with a complex geometry, as well as for molds with internal cooling channels and components where material savings are made through cavities or pockets. Very high precision is possible and fine details can be produced.

In the field of plastic printing, we use the processes: FDM (Fused Deposition Modeling, i.e. melt layering), MJF (Multi Jet Fusion) and SLS (Selective Laser Sintering). For metals, we use SLM (Selective Laser Melting) technology. For the necessary preparation of your data, we use different CAD programs, e.g. GrabCAD and Materialise Magics. We use Netfabb for the optimal utilization of the construction space. We would also be pleased to support you in the 3D print-compatible design of your components and to enable cost-effective manufacturing in order to take advantage of the benefits of additive manufacturing already in the early phase of product development.

Materials used:

Plastics:

  • standard plastics
  • engineering plastics
  • high performance plastics

Metal:

  • aluminum
  • stainless steel
  • titanium
  • other materials on request

For the respective materials processed, please refer to the separate processes listed below.
 

Processes

In additive manufacturing, we offer the following processes:

PLASTIC 3D PRINTING
FDM FDM

Used for massive and large components (e.g. large containers for oils or chemicals), small series (prototypes) as well as devices and manufacturing aids. Also ideally suited for components made of high quality thermoplastics which are especially needed in demanding industries such as medical, aerospace, research and defense.


Our material portfolio includes the following materials:
Standard plastics:

  • ASA (UV resistant)
  • ABS-M30 (good strength and flexibility)
  • ABS-ESD7 (antistatic)

Engineering plastics:

  • PC (high tensile strength) 
  • PC-ABS (high impact resistance)            
  • Nylon PA12 (high fatigue strength + resistance)
  • ST-130 (tooling, soluble material for cores) 
  • Nylon PA12 CF (carbon fiber reinforced)

High temperature plastics:

  • Antero 800 (PEKK)
  • ULTEM9085 (PEI, FST certified)
  • ULTEM1010 (PEI, temperature resistance up to 210 °C, highest chemical resistance); NSF 51 (FDA approval)

Biocompatible plastics (ISO 10993/ USP Class VI)

  • ABS-M30i
  • PC-ISO
  • ULTEM1010
     
MJF MJF

The MJF process is a low-cost alternative to injection molding.
Used for small and medium series production. For components with a high level of detail and surface quality. Ideal for functional prototyping and small series production, suitable for serviceable components, due to high wear resistance.

The following materials are available
PA12

  • very resistant material (chemical resistance, mechanically stable, heat resistant up to ~ 100 °C)
  • biocompatible
  • for robust, low-cost, high-quality parts
  • Thin structures are flexible, while thicker structures are rigid.

PA11

  • moldable, high quality parts
  • biocompatible 

PA12 GB

  • rigid, dimensionally stable, high-quality parts
  • chemical resistance to oils, greases, alkalis

TPU

  • flexibility and high elongation at break 
  • high abrasion resistance and elasticity 
  • well suited for prototyping and series production
     
SLS SLS

Ideal for visual and functional prototypes, operational and robust small series, complex component geometries, chemical resistant components (PP material) and trade show models

The following materials are available:
PA12 (PA2200)

  • very resistant material (chemical resistance, mechanically stable, heat resistant up to ~ 100 °C)
  • biocompatible
  • for robust, low-cost and high-quality parts
  • Thin structures are flexible, while thicker structures are rigid.

PA11

  • moldable, high-quality parts
  • biocompatible

PP (polypropylene)

  • high elongation at break and flexibility 
  • durability and toughness
  • low weight
  • high chemical resistance

Duraform PA  

  • high level of surface quality and detail
  • for medical applications, meets USP Class VI requirements and is biocompatible
  • good chemical resistance and low moisture absorption
     
Metal 3D Printing
SLM SLM

For the production of high-quality metal parts with a density of more than 99.5% from stainless/tool steels as well as aluminum and titanium alloys in the field of prototypes and series.

The following materials are available:
Aluminum

  • AlSi10Mg, AlSi7Mg06, AlSi9Cu3

Steel

  • 1.4545 (15-5PH), 1.2344 (H13), 1.4542 (17-4PH), 1.4404 (316L), 1.2709, 1.23912 (Invar36)

Titanium

  • Titanium: TA15 (near-alpha titanium), 3.7035 Ti Grade 2, 3.7165 TiAl6V4
POST-PROCESSING
Powder removal Powder removal

After printing the component, the installation space around the workpiece must be cleaned from the loose metal powder. For this purpose, we use special machines and industrial wet vacuums that are suitable for explosive metal powder in order to avoid a reaction or spontaneous combustion.

Heat treatment Heat treatment

The SLM process creates stresses in the component. These can be reduced by heat treatment which can also improve the mechanical properties of the alloy. For the different materials, such as aluminum, tool steel, stainless steel and titanium, the chamber furnaces must meet certain requirements. Especially for oxygen-sensitive materials, such as stainless steel or titanium, high-quality furnaces with an oxygen-free atmosphere must be used.

Detaching the component from the build plate Detaching the component from the build plate

After the component has been heat-treated, it can be detached from the build plate. The component is separated from the build plate by cutting through the support structure. Remaining powder in the support structure is released while sawing and must be extracted again.

Finish Finish

We offer a variety of finishing processes in-house: 
Manual finishing is carried out exclusively on workplaces with a central suction system in order to remove the remaining powder and the support structure of the component. At the same time, manual finishing takes place at the points where the support structure was bonded. In the plastics sector, the support structure can sometimes be loosened by appropriate baths without manual intervention.
In case of higher requirements for tolerances and dimensional accuracy, the components must be additionally machined in-house using lathes or milling machines as SLM components are manufactured with a maximum tolerance of ± 0.2 mm.
Other mechanical machining operations include: Drilling, thread cutting, hot pressing, joining of components. We offer these processes for metal and plastic parts. If desired, the components can also be mounted to form complete assemblies.

Surface finishing Surface finishing

The following processes are available in-house and with certified partners:

  • blasting with sand and glass beads
  • grinding
  • barrel finishing/sliding grinding
  • galvanizing (chrome plating)
  • manual or electrochemical polishing
  • sealing of the surface by means of acetone smoothing
  • filling and varnishing, including the application of special protective coatings for the production of antistatic (ESD) and/or electromagnetic compatible (EMC) surfaces
  • AFM (abrasive flow machining)
  • co-pulse

This is followed by quality inspection and the desired surface finishing.
 

Advantages

Additive manufacturing shows its strengths where conventional manufacturing reaches its limits:

  • fast manufacturing process (a component can be ready in a few hours!)
  • production on demand (no stock-keeping necessary, changes are possible at short notice)
  • high performance materials in use
  • high strength (close to forged metal parts)
  • geometrically complex and light at the same time

YOUR additional benefit - a quickly available, completely ready-to-install component from a single source - made by RILE
 

Manufacturing examples

Discretion is a matter of course for us!

Due to secrecy agreements and a natural, self-imposed duty of confidentiality, we are only allowed to show approved customer parts.

We would be pleased to convince you of our skills and production possibilities in a personal conversation.

Industrial 3D printing - file upload

Formular

Information about file formats

  • all common CAD formats possible, e.g. step file, STL file, CAD file 
  • input of the material 
  • requirements for the model
  • scale e.g. 1:1, 1:3, 1:5 for trade show models
  • file size up to max. 25 MB. For larger files, we can provide a link to upload on our RILE box.