Low-noise motion simulator thanks to 3D printing filaments and linear plain bearings

Like many fans of simulated car racing, Mr Krebs usually only has time for his hobby after work. However, the noise emitted by the simulator can be disturbing for other household members or even neighbours. On the one hand, the noise is caused by the humming of the engine, which is why he has installed a new soundproofed engine. Unwanted noise is also caused by the metal ball bearings during linear movement on the shafts and actuators of the simulator. The same applies to ball screw nuts, which are guided along rotating threaded spindles. The declared aim was therefore to reduce the friction between the components and thus minimise noise pollution.

The self-lubricating specifications of the igus®-plastic enable smooth and low-noise sliding. The standard linear plain bushes drylin® R RJUM-01 and RJM-01 ​​​​​were used as a replacement for ball bearings. The bushings of the RJUM-01 model fitted perfectly when they were mounted in the bearing blocks 3D-printed by Mr Krebs. Where the standard sizes of the drylin® linear bushes did not fit, bushes were 3D printed from iglidur® i150 filament and also mounted in bearing blocks. The 3D printing also made it possible to manufacture lead screw nuts from iglidur® i190, which are similar in design to the original metal ball nuts.

The friction between a lead screw nut and a threaded spindle can be creatively tested by first supporting the lead screw nut vertically on metal rods. The spindle is then positioned in the lead screw nut so that its weight presses on it. It is then checked whether the lead screw driven by a stepper motor can rotate despite its vertical suspension. This would be a clear indication that it is not blocked by its weight and can therefore rotate with low friction under normal conditions in the simulator. As can be seen in the video, the suspended spindle can rotate without restriction within the lead screw groove printed from iglidur® i190.