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3D Printing of Micro Flat Fan Nozzles
Precise Cleaning Solution for the IBAK Cutter's Camera System
Customer challenge
As part of the redevelopment of the IBAK cutter, the company required a compact and high-performance cleaning solution for the integrated camera system. The objective was to reliably clean the camera lens during operation by means of a targeted flushing process. The main challenge was the extremely small size of the design: at its narrowest point, the nozzle channel was required to measure only 85 μm. At this scale, no commercial flat-fan nozzle solution was available on the market. In addition, the design required an angled nozzle channel, which could not be manufactured using conventional production methods such as injection molding.
The answer: Additive manufacturing
From the early stages of product development, IBAK considered additive manufacturing. As they evaluated various SLA technologies in terms of precision and material performance, the best results were achieved with our Hot Lithography process on the Caligma® system. Only this technology was capable of delivering the required resolution and sharp edge definition of the nozzle channel. The selected material was also highly suitable, offering low water absorption and stable mechanical properties – even under continuous exposure to water, temperatures of around 70 °C, and repeated thermal cycling.
The result
IBAK successfully established series production of the high-precision micro flat-fan nozzles and integrated them into the new cutter head. The nozzles manufactured in 2020 are still in operation today, consistently meeting all performance requirements in the demanding environment of pipe cleaning applications.
Customer benefits
• Implementation of extremely fine geometries with highest precision
• Reliable performance thanks to sharp edge definition and an excellent spray pattern
• Durable material properties under exposure to water, temperature, and mechanical stress
• Efficient serial production with low scrap rates
• Fast development cycles enabled by additive manufacturing technology
IBAK Helmut Hunger GmbH & Co. KG, based in Germany, is a leading international manufacturer of inspection and rehabilitation systems for pipeline and sewer technology. The company has stood for the highest quality standards and technological expertise in the field of sewer systems for decades.
Have we sparked your interest?
Our sales team will be happy to advise you personally on materials and the right industrial 3D printer for your application. We look forward to hearing from you!