3D printing

Before thinking about tools or series production, RICO Group focuses on a decisive development step: the 3D-printed prototype. This additively manufactured model is the first tangible draft of the planned component and offers many advantages - especially for complex silicone parts.

Location:

RICO

REALITY YOU CAN TOUCH - PROTOTYPING WITH PRECISION AND SPEED

The aim is a quick, practical check of:
Geometry: Does the shape correspond to the CAD data? Are there any critical transitions or demolding problems?

Function: Does the part fulfill its technical function - for example as a seal, valve or housing component?

Haptics & ergonomics: How does the part feel? How flexible or stiff is it? This is particularly important for medical or consumer applications.

Assembly check: Does the part fit into the end product? Does it work together with other components?

Why 3D printing?
Flexibility is crucial in the early development phase. With 3D printing (e.g. stereolithography, DLP or MultiJet), prototypes are created in just a few hours - without any toolmaking. This saves time and costs and enables fast iterations:

- Design changes can be implemented immediately
- Variants can be compared
-Feedback can be integrated directly

Especially for silicone parts with fine contours, thin walls or flexible elements - such as sealing lips, membranes or micro-buffers - a physical model is irreplaceable for the assessment.

3D printing tool
Once the prototype has been successfully validated, the next step follows at SILCOPLAST: the 3D printing tool. This uses an additive process to create a negative mold - made of heat-resistant plastic or metal (e.g. DMLS).

This allows the first components to be produced using the real injection molding process with original material (LSR - Liquid Silicone Rubber). The tool is clamped in a test injection molding machine and used as in the later series production process.

Why is this important?
A conventional steel tool is expensive and time-consuming. Errors in it can lead to expensive reworking or new production. The 3D printing tool acts as a realistic "dress rehearsal" - with low risk and high flexibility.

This means that the subsequent series tool - e.g. the hardened tool from HTR - is based on a validated and approved geometry.

Advantages:

- Realistic process simulation: material behavior, flow behavior, deaeration, weld lines detectable at an early stage

- Check demoldability: Problems with adhesion or geometry become visible

- Sprue optimization: position and venting can be tested - without costly changes to the series tool

- Material tests with LSR: properties such as Shore hardness, transparency or recovery can be tested