Prototyping, small-batch production, and mass production – all using injection molding pellets
Material diversity – We can process these pellets
The number of plastic pellets to choose from is huge. There are a few thousand just for injection molding. This pyramid shows the types we can already qualify.
But what does that really mean? We have a growing and already large selection of qualified pellets (like the PA, PPS, and TPE shown above). “Qualified” means that we – or our customers – are already printing components reliably with them. But we are not stopping there. We want to conquer the entire plastics pyramid and continue to grow — together with you. That's why we also show materials here that are not yet “qualified” but are “qualifiable.” This means that we see a very high chance to print your choosen plastic pellets from this area.
How do we do this? We offer our customers what we call “material qualifications.” We test your preferred pellets—from the green and orange types in this pyramid. If the validation is positive, we will then print an individual sample part in your preferred material so that you can see the quality for yourself. We recommend choosing an injection molding pellet that you already use in injection molding for series production. This will give you and your company an individual competitive advantage: from now on, you will be able to work with your preferred material for everything from prototyping and small series to series production and even spare parts. Sounds good, right? A clear win-win. You stay one step ahead of the market and we conquer the plastics pyramid and expand our range of already qualified materials.
Strict requirements? Certifications? Standards? No problem!
There is already a suitable, proven injection molding compound available for just about every standard, no matter how stringent. Thanks to our award-winning melting process, which is particularly gentle on the material, these valuable material certifications and standards are preserved in the printed component – from flame-retardant and radar-absorbing to ESD. This has also been confirmed by tests conducted in external laboratories.
Use cases from our customers industries
You can also find current use cases with 360° photos on our website. Or by scanning the QR code on our trade fair website.
Automotive – PA6 GF30 HI
Typical series materials such as PA6 with fiber filling up to 50% are used here. Prototype to series production.
Railway – TPE Shore 50A FR
Certified flame-retardant material for passenger transport. Also complies with DIN EN45545-2 standard.
Plastics manufacturing – PA6 CF30 (ESD)
Despite fiber filling, it has a great surface. It can also withstand high operational demands.
Prototype construction – PPS GF40 (chemical resistant)
Thermally stable, chemically resistant, and low in ions. Withstands mechanical stress (such as operating and vibration loads) and is also gas-tight.
Orthopedic Technology – TPE 32 Shore 00
A particularly soft, gel-like material, e.g., for custom shoe insoles or wheelchair seat cushions. Durable materials for protective helmets or orthoses are also available.
Your Industry – Your Material
Can't find your industry here? No problem! Our customers' industries are as diverse as our range of materials. So feel free to contact us with details about your industry, your standards, and your material requirements, and we'll advise you on the options available.
BMW Motorrad – Triple clamp – PA6 GF30 HI
The component shown here is a sample of a 3D-printed triple clamp for BMW Motorrad. A triple clamp connects the fork legs securely to the frame and handlebars in order to transmit steering movements, guide the front wheel, and ensure the rigidity of the front suspension.For pass checks in an early development phase, we were able to create sample components for BMW Motorrad here. We used PA6 GF30 HI to achieve the best possible fit.
In addition to its precise fit, the material also impresses with its attractive look and feel.
Robert Bosch GmbH – Fuel Cell – PPS GF40 – Chemical Resistant
As one of the world's largest automotive suppliers,
Bosch
has extensive expertise in the
automotive
sector. This component is part of a
fuel cell
and was manufactured using 3D printing from the
high-performance plastic PPS GF40.
The glass fiber-reinforced polymer material meets
the high requirements of modern fuel cell systems,
particularly in terms of
thermal stability, chemical resistance, and low ion
content.
An intelligent infill strategy and precise monitoring of
temperature and pressure result in components that not
only
withstand mechanical stresses such as operating and
vibration loads, but are also gas-tight.
The ability to process high-performance polymers such as PPS demonstrates the capabilities of the Bosch Pellet Printer and opens up new potential for customers from a wide range of industries—from the development of robust prototypes to the production of functional series components.
Österreichische Bundesbahnen ÖBB – Gasket seal – TPS Shore 50A – Flame retardant Railway
The component shown here is a membrane seal for Österreichische Bundesbahnen – Technische Services. It is integrated into the locks of gangway doors. Its primary function is to protect the internal mechanics from external environmental influences (such as water and dirt). It was manufactured using the Bosch Pellet Printer with TPS Shore 50A. This makes the component particularly flexible and ensures that it meets the demanding requirements of the DIN EN45545-2 standard. In addition, the material retains its sealing effect for years thanks to its high resilience. Switching to the additive-manufactured version also results in significant cost savings.
Special material properties – outstanding components. Which material certification will give you a competitive advantage in the future?
WEIDPLAS GmbH – Air cap control system – PA6 GF30 HI
This particularly delicate component is an
air flap control system
(main frame and associated mounting components). It is a
central component of the
HVAC system.
It determines where the
air is directed in the vehicle
interior. The system must meet
high mechanical properties,
functional reliability,
and strict tolerances.
The system was printed from PA6 GF30 HI, the intended
series
production material.
Thanks to the pellet-based Bosch Pellet Printer, prototypes can be manufactured directly from the material that will later be used in series production, allowing functionality and material behavior to be tested under realistic conditions.
Robert Bosch GmbH – Vakuumgreifer – PA6 CF30 – ESD zertifiziert
The use of 3D printers is particularly advantageous in
special-purpose machine construction
, as prototypes can be produced
quickly, cost-effectively, and precisely
— ideal for flexible development and early testing of
customized solutions.
The Bosch Pellet Printer
produced these vacuum grippers made out of PA6 CF30 for
a division of Robert Bosch GmbH. The component impresses
with its excellent
ESD properties, high dimensional accuracy, and superb
surface finish
— properties that are essential for safety-critical and
precise handling tasks. Thanks to the Bosch Pellet
Printer, our colleagues in Hungary were able to
quickly and cost-effectively
manufacture components that meet the
high operational requirements.
Always one step ahead of the competition – with the Bosch Pellet Printer.
ZIEHL ABEGG SE – Radial impeller – PA6 GF30
This image shows a radial impeller from ZIEHL ABEGG SE. In addition to its frequent use in air conditioning and ventilation technology, the radial impeller is also used in residential ventilation, roof fans, and indoor heat pumps. The focus for this component was on enabling high volume flows. The component was printed from polyamide 6. Even large components and complex geometries with overhangs can be produced with the Bosch Pellet Printer. This will enable ZIEHL ABEGG to manufacture various impellers and other components in the original material in the future, thus replicating near-series material properties as early as the sample phase or in small series.
This closes the circle, from sample to series part – all in one material.
Proof? Proof! Here are a few of our favorite success stories
Use cases from orthopedic technology and mobility/automotive. Take a look at our customer applications and go behind the scenes.
Note: Several videos are clickable in the navigation bar. Enjoy watching!
Clear price advantage, no material lock-in
We do not sell our own expensive “special” and 3D printing-optimized materials, but instead enable our customers to process proven and constantly available standard plastic pellets (such as injection molding pellets), which are often already used in their companies. In terms of price, these standardized injection molding pellets are significantly lower than the prices of our competitors.
Here is a small price comparison of common 3D printing processes using the example of a standard material PA6 GF30:
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