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3D Printed Fuse Box with PBT Technology.
Case Study

Discover the power of 3D printing for electrical and electronic components.

April 03, 2023
3D Printed Fuse Box with PBT Technology.

The Task: Enable 3D printing for electronic and electrical parts.

Transforming Design and Production for Manufacturers

Additive manufacturing (AM) or 3D printing is already enabling car makers and auto electronics manufacturers to completely rethink their design and production processes. It is now possible to produce fully functioning electronic prototypes, end-use spare parts, and small-series components without expensive injection molding techniques. 3D printing also has the potential to save on material, energy consumption and shipping costs.

Understanding Polybutylene Terephthalate (PBT) for 3D Printing in Auto Electronics

Polybutylene terephthalate (PBT) is a commonly used material in traditional injection-molded electronic auto parts, thanks to its good performance under a wide range of temperatures and in moist environments. Our task here was to offer customers a material that meets their needs for 3D-printed electric and electronic car components, which can be processed for industrial production.   

 

Advantages of PBT for 3D Printed Electric and Electronic Car Components

This material offers customers a solution that brings higher accuracy and productivity, and lower cost per part. This solution also helps customers print more parts in the same amount of time, leading to lower costs per part and increased productivity, combined with higher accuracy.

The Challenge:

High-performance 3D-printed material for electronic parts.

Mechanical Requirements for Automotive Components

Components for automotive, industrial and power electronics must meet a wide range of stringent mechanical requirements as they affect occupant safety. These parts must withstand both short- and long-term exposure to high temperatures, ensuring there are no power breakdowns, leakages or short circuitries. 

Challenges of Material Selection for Car Fuse Boxes

Car fuse boxes bring a particular set of material challenges, as their function is to protect and insulate a vehicle’s electrical and electronic circuits from exposure to outside elements, while also regulating the current that flows through the wiring to each component. The fuse box material must deliver electrical and mechanical properties, as well as resistance to high and low temperatures.

3D Printed Fuse Box Using PBT 3D Printers.

PBT as a Solution for 3D-Printed Car Fuse Boxes

PBT has long been a preferred option for traditional injection-molded electronic parts. The challenge here was to find the right material for a 3D-printed car fuse box that delivered all of the required technical characteristics.

The Solution:

SLS 3D printing meets PBT: Addigy® P1210 PBT powder.

Taillight 3D printed using Addigy P1210.

Introducing Addigy® P1210 PBT Powder for 3D Printing

Addigy® P1210 is a PBT powder engineered specifically for 3D printing using selective laser sintering (SLS) technology. This innovation means electronic components, such as an automotive fuse box, can now be 3D-printed with the same material used in traditional manufacturing. 

 

The Advantages of Combining Addigy® P1210 PBT and SLS Technology

Combining Addigy® P1210 PBT with SLS technology, provides manufacturers a proven solution well-suited for electronic and electrical components that must meet demanding thermal exposure, dielectric and mechanical criteria. 

 

Revolutionizing Electronic Volume Production with Material Expertise

Without the need for extensive tooling, low-volume parts and prototypes can be produced more quickly and cost-effectively than with traditional techniques. Material waste, processing and shipping costs are reduced. This is an example of how material expertise can enable the additive manufacturing revolution in electronics volume production.

 

Addigy P1210 Product Page

Addigy® P1210 is one of the first commercially available PBT powders for selective laser sintering. The ideal solution for small series production via additive manufacturing in industrial applications such as 3D printed automotive electronics.

Addigy® P1210

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