Gears are key components of many mechanical systems, from machine drives and robot positioning systems to gear units in vending machines. As system complexity increases, demand grows for custom, durable components with high manufacturing precision. The new iglidur i4000 3D printing resin from igus is a response to these requirements, developed specifically for gear applications. The material, designed for DLP processes as well as SLA and LCD printers, has been engineered to provide high wear resistance, increased flexibility and stable performance under long-term loading conditions. Compared with standard 3D printing resins, iglidur i4000 offers 13 times higher elongation at break and five times longer service life, as confirmed in the manufacturer's laboratory tests.
Development of 3D printing materials for tribological components
Three years ago, igus, a company specializing in plastics for motion applications, introduced its first 3D printing resin, iglidur i3000. This material enables the production of wear-resistant parts using the DLP process while maintaining high resolution and dimensional accuracy. According to the company, recent years have seen a clear increase in demand for lubricant-free gears in a wide range of shapes and sizes.
"Over the last two years, we have observed growing demand for lubricant-free gears in various shapes and sizes. Resins are a very good solution, because the process allows the production of components with quality similar to those obtained by injection molding," explains Michał Sędrowski, Manager Gears and 3D Printing iglidur at igus.
According to the manufacturer, photopolymer resin printing technology enables fast and repeatable production of components with complex geometries, while maintaining tolerances that are critical for gear meshing. This is particularly important when the tooth geometry must be adapted to a specific application or to the design constraints of the device.
iglidur i4000 for gears with increased performance requirements
Based on experience with the first resin and on customer feedback, igus has developed the new iglidur i4000 material aimed at gear applications. This resin has been designed to provide increased wear resistance and mechanical properties that allow operation under continuous load and motion.
"This resin is ideal for producing gear prototypes, especially in early development stages, when the goal is to validate concepts or principles, because production by DLP is fast and economical. Individual adjustments can be made in a very short time," says Sędrowski. The material is suitable for DLP, SLA and LCD printers.
The possibility to use iglidur i4000 in DLP, SLA and LCD printers increases flexibility in choosing the technology depending on project requirements, available equipment or the expected process throughput. In practice, this enables the manufacture of prototype series, short production runs and special components for which conventional methods, such as machining or injection molding, would be economically unjustified or time-consuming.
Performance parameters and laboratory test results
Standard 3D printing resins, despite favorable strength parameters, are often not designed for the specific operating conditions of gears, where cyclic loading, contact of working surfaces and long-term durability requirements all play a role. For iglidur i4000, the goal was to tailor the material characteristics to the loads occurring in gear units.
"Our resin has been specifically designed to meet requirements for performance, flexibility and stability," explains Sędrowski.
According to igus, iglidur i4000 is characterized by high wear resistance and significantly increased elongation at break, which is particularly important for gears exposed to continuous loads during operation. Tests carried out in the company's 5500 m2 laboratory showed that, compared with iglidur i3000 and high-strength standard resins, the new material provides five times longer service life and 13 times higher elongation at break.
In practice, this enables the design of 3D printed gears for more demanding applications while reducing the risk of failures resulting from material brittleness. According to the manufacturer, this extends the use of additive manufacturing technologies in gear and drive applications, where metal components or conventionally manufactured plastic parts have been more common.
Self-lubricating properties and no need for maintenance
An important feature of iglidur i4000 is the self-lubricating nature of the material, which eliminates the need for additional lubricants such as greases or oils. As a result, gears made from this resin do not require lubrication or periodic maintenance in this respect.
This can be relevant in applications where access to the gear unit is difficult or where the use of lubricants must be limited, for example for hygienic or design reasons. Using a self-lubricating material also reduces the risk of environmental contamination by lubricant and simplifies the design of covers and sealing systems.
The company reports that the first customers are already using the new resin in their applications, which indicates the suitability of the material under operating conditions. iglidur i4000 is intended primarily for gear applications, but its tribological and mechanical properties may also be relevant for other components operating in sliding motion.
Applications and access to information
The new resin was developed in close cooperation with customers, which made it possible to tailor its properties to specific application requirements. This particularly applies to systems where the combination of high manufacturing precision, wear resistance and the ability to operate without additional lubrication is important.
In practice, iglidur i4000 may be used in gear units for automation, robotics, special-purpose machines or vending equipment, wherever custom-geometry gears are required, produced in short series or within rapid prototyping workflows.
More information on 3D printing at igus and on available materials and services can be found at: https://www.igus.pl/druk-3d.
iglidur i4000 has been specially designed for the production of wear-resistant and precise gears. Compared with standard 3D printing resins, it offers 13 times higher elongation at break and five times longer service life.
