Lock shaft - serial production by 3D printing from cotu s.r.o.

Series Production Using 3D Printing - The Challenge of Developing a Lock Slider for ASSA ABLOY
 

For ASSA ABLOY's engineers, finding a more efficient process for developing lock sliders was a real challenge. Current methods, such as creating prototypes by injection moulding in metal moulds, were costly and time-consuming. Finding an alternative technology was difficult, as it had to meet several key requirements, including the need for a durable material with a long service life, capable of withstanding 120 000 lock unlocking cycles while also providing a high-quality surface finish. After an unsuccessful internal investigation, they turned to Cotu, an experienced provider of SLA 3D printing services for industrial sectors.

How Cotu Decided to Address This Challenge

Technology used: Asiga MAX DLP 3D printer
Material used: LOCTITE 3D 3843 HDT60 High Toughness Matte Black

Cotu drew on its expertise in premium SLA materials and selected LOCTITE 3D 3843, which was the optimal choice for meeting the client's requirements. High precision and meticulous execution were crucial for the intricate lock mechanism. Each part had to be manufactured to fit precisely onto the motor shaft. By drawing on Cotu's experience in R&D and blending photopolymers and nanopigments, it was possible to achieve even higher resolution, ensuring precise reproduction of even the most demanding details. As a result, the parts did not need to be bonded, any play was eliminated and a secure connection to the motor shaft, measuring just 0.5 mm in diameter, was ensured.

Lock slider for ASSA ABLOY

cotu 3D Printing - Speed and Cost Savings
 

The Asiga MAX 3D printer was selected for its ability to consistently produce parts with high precision and a high-quality surface finish. Thanks to its sensors, it was possible to print components with precise tolerances for fitting. This would be practically impossible with a standard LCD 3D printer, which does not have these sensors. The integration of sensors enables extremely accurate dimensions and production repeatability. This is crucial for producing miniature lock components of the required quality.

With the help of the Asiga MAX 3D printer and LOCTITE 3843 material, costs and production time were significantly reduced. Unlike the conventional plastic injection moulding method, where preparing the mould would take at least a month, 3D printing made it possible to produce 500 parts in just 15 minutes and deliver them in the same week. The 3D-printed parts were highly precise and enabled more tests to be carried out in the early stages of development, significantly reducing the number of defects in the final products.

Cotu is a leading company in 3D printing and additive manufacturing, providing comprehensive services from design through to series production. It specialises in stereolithography (DLP and LCD), which accelerates production and makes it more efficient, and also offers other technologies such as SLS, MJF and FDM. It works with renowned brands such as Asiga, Phrozen, BASF, Loctite and Evonik. In the field of SLA, Cotu excels not only in its know-how in delivering initial production, but also in the effective implementation of cutting-edge technologies thanks to proven production procedures, which it also shares through comprehensive training. The company's vision is to become a leader in stereolithography, continuously innovate production processes and push the boundaries so that its customers achieve a competitive advantage and unique production results.