FAQs - Frequently asked questions about
3D printing at igus

General information about 3D printing

The 3D printing service at igus

The 3D printing materials from igus

3D printed gears

Food-compliant 3D printing

What is 3D printing?

3D printing refers to manufacturing digitally defined objects by means of layered application and bonding of material. The term "3D printing" is often used colloquially as a synonym for additive manufacturing. Additive manufacturing methods contrast with subtractive ones, such as machining, in which material is removed.

What are the types of 3D printing available?

The best-known 3D printing methods are fused deposition modelling (FDM), selective laser sintering (SLS), selective laser melting (SLM), stereolithography (SLA), digital light processing (DLP) and multi-jet modelling/polyjet modelling. In the igus 3D printing service , materials are processed with the SLS, FDM and DLP processes.

How does 3D printing work?

Manufacturing an object with a 3D printing method requires at least three steps:  

1. The object is created digitally in a CAD file and converted into a format that the 3D printer can read (e.g STL)
 2. The object is printed in layers
 3. The finished object is cleaned and reworked as necessary (polishing, coating, colouring, etc.)

The exact production technology depends on the printing method. There are many methods that are primarily distinguished by whether the material is added in the form of powder, molten plastics, or fluid and whether they are cured by light, air, or bonding agent. Depending on application, plastics, metals, ceramics, concrete, food or even organic materials can be processed with additive technologies.

When does 3D printing make economic sense?

3D printing is the manufacturing process of choice for complex-geometry parts, small batches and prototype development, since the fixed costs are much less than traditional manufacturing processes. Depending on component geometry, however, 3D printing can also be the cheapest process in large-series applications. Die casting or injection moulding requires a mould that can be used only to produce a specific part. Before the next part can be produced, the mould must be replaced and the machine refitted. These costs must first be calculated based on the number of parts produced. 3D printed objects can also be produced in a very short time. For example, a 3D printed spare part can significantly reduce or even eliminate the costs of machine failure due to a defective part, since it is available more quickly and is often cheaper to produce.

What is industrial 3D printing for?

Industrial 3D printing is used for manufacturing prototypes, tools, and series parts. It uses materials that, depending on the industrial application in question, must meet special mechanical requirements, e.g. flexibility, rigidity, and wear resistance.
3D printing has proven very economical in industry because models and small batches can be produced, tested, and adjusted for large volume production much quicker than they could with usual methods. Unlike prototypes that map only the geometries of the planned component, industrially manufactured 3D printed models allow all mechanical properties to be tested on the machine.

What are the advantages of an external 3D printing service?

3D printing services are frequently used for industrial prototype manufacture, since procuring an industrial 3D printer is not cost-effective unless the company in question possesses the necessary expertise and uses the printer regularly to manufacture models and series. 3D printing service providers usually have not only the necessary expertise, but also several 3D printers, allowing them to select the method best suited to the application in question. Depending on method, it is also much more cost-effective to engage an external service provider because such methods as laser sintering involve the regular manufacture of large batches of parts for various customers, greatly lowering production costs for individual parts and thus for individual customers.

1. Questions about SLS 3D printing 🔽

2. Questions about FDM 3D printing 🔽

3. Further questions about the 3D printing service at igus 🔽

What are the advantages and disadvantages of laser sintering component surface finishing?

The vibratory finishing minimally removes particles from the surface and can, for example, anticipate the shrinkage of a plain bearing point. It is a cost-effective and quick form of after-treatment, but is ineffective in places that the sliding bodies do not reach (e.g. inner edges, channels). The process is only suitable for smaller components with simple geometries. The chemical smoothing process dissolves the plastic on the surface of the component. After the solvent has evaporated, a dense surface remains, while the untreated component always has a certain porosity, which plays a role in the use of lubricants, adhesives, compressed air as well as vacuum. This surface finishing produces even smoother surfaces than vibratory finishing, but also means a higher surcharge and a longer delivery time of the component (9-12 working days). Both surface finishes can be configured and ordered directly online in the iglidur Designer under the "Finishing" tab.

A chemically smoothed roller from the igus 3D printing service

Is it possible to rework FDM components?

Post-processing steps such as mechanical finishing (drilling, turning, milling) and the setting of thread inserts is also possible for components made in the FDM procedure. Feel free to contact us using the contact form if you need support for your application in this regard.

Can the surface of the components produced by FDM 3D printing be smoothed?

This is possible for some tribofilaments and has already been tested experimentally. For an assessment of your individual application, please contact us using the contact form.

Besides igus tribofilaments, what materials are available in the 2K or 4K printing service?

In addition to the tribofilaments, a number of other filaments, e.g. a flexible material (TPU) and other types of materials are available for the multi-material 3D printing service. If you are interested, please feel free to contact us using the contact form .

2K component from the igus 3D printing service

Can threads be printed in the 3D printing service?

Fastening threads can be printed directly from M6 or comparable dimensions. For this, the geometrical shape must be integrated in the 3D model. Alternatively, threads can also be cut or, in the case of heavily stressed or frequently screwed threads, threaded inserts can be used. Please request a separate quotation for this.

Can drive threads be printed in the 3D printing service?

Upon request, igus can provide components with threaded holes for trapezoidal or dryspin lead screws. Lead screw nuts for trapezoidal threads can be generated with the igus CAD configurators. For dryspin threads, please contact us using the contact form as this is a protected geometry.

What must be observed when using the printed components in a vacuum?

Due to the integrated solid lubrication, igus plain bearings also function in a vacuum. Depending on the application, the maximum permitted gas release on the plastic component must be reduced to a minimum. Due to the higher density, the laser sintering process is recommended here rather than the FDM process. The gas release of laser sintering plastic components can be reduced by first drying and then infiltrating the parts. Both can be offered by igus and carried out directly during production.

Are 3D printed components from igus gas-tight?

So far, igus has been able to gain experience with components produced using the laser sintering process. It is known that untreated components do not have a high gas tightness. Gas tightness can be significantly improved by an infiltration process or by chemical smoothing, which has already been confirmed by customer feedback. However, the gas-tightness always depends on the wall thickness; the thicker the wall, the more gas-tight the component. For components produced by filament printing, a lower gas tightness can be assumed, therefore the laser sintering process is recommended here.

Can igus produce spare parts?

If a 3D model exists and there are no legal claims from the original manufacturer, this is possible. For commercial customers, igus offers to rebuild defective components. Private customers have the opportunity to have the component redesigned and manufactured via local initiatives for 3D repair. For simple parts such as plain bearings and gears, the igus CAD configurators can also be used.

How does the service life calculator in the 3D printing service online tool determine the expected service life for parts made from the 3D printing materials?

The data base for the igus service life calculators are the results of the 11,000 wear tests that igus performs annually in its own 300m2 test laboratory.

Does the SLS/FDM heat affect the self-lubrication of the components?

No, it does not. The solid lubricants are not affected by the heat. The same is true for injection moulding and bar stock materials, which also experience intense heat briefly during the manufacturing process without losing their self-lubricating properties.

igus does not manufacture any metal parts with the 3D printing service.

1. Questions about laser sintering powders 🔽

2. Questions about igus filaments 🔽

3. Further questions about the igus printing materials 🔽

On which 3D printers can the iglidur laser sintering powders be processed?

igus uses the EOS Formiga P110. Fundamentally, laser sintering 3D printers with CO2 lasers should be able to process iglidur i3 and iglidur i6 if the printing parameters can be adjusted. There has already been positive feedback from customers with EOS Formiga P100 and 3D systems equipment. Due to the different absorption of the laser energy, it is not suitable for low-cost systems such as Sinterit Lisa or Formlabs Fuse 1. iglidur i8-ESD with its black colour is suitable, and customers have already given positive feedback.

So far, I have always purchased components made of PA12 or from the MJF process. Which igus laser sintering powder is comparable?

All iglidur laser sintering materials are fundamentally suitable, but the most suitable material for specific requirements can be selected. iglidur i3 is the most frequently selected and the most cost-effective laser sintering material in the igus 3D printing service.

Is there a coloured powder? What colours are available?

The best-selling laser sintering powder iglidur i3 is beige/yellow. We also offer powder in white (iglidur i6), black (iglidur i8-ESD) and anthracite (iglidur i9-ESD). For other colours, the printed components can be subsequently coloured in the 3D printing service. 

What surface finish is achieved during 3D printing with laser sintering powders?

The roughness of sintered materials is quite high, but it smooths quickly with use and does not affect the performance of the printed part.

Can I process igus filaments on my 3D printer?

In most cases, yes, as long as the 3D printer allows the processing of third-party materials. If the printing parameters (speeds, temperatures, etc.) can be set yourself, there is nothing to be said against it. The processing instructions can be found in the download area on the product page of the respective material in the shop.

What filament diameters does igus offer?

Filaments from igus are available in diameters of 1.75mm and 2.85mm. Some 3D printers require 3mm diameter filament. In practice, this refers to the diameter 2.85mm, so it should be used synonymously. Therefore, the igus "3mm filament" can be used on printers that require 2.85mm or 3mm filament. Only the high-temperature filaments (iglidur RW370, A350 etc.) are currently only available in 1.75mm.

Can igus filaments be processed on Stratasys/Makerbot/Markforged printers?

No, because these manufacturers, like some others, only allow the use of their own filaments.

What are the dimensions of the spools of tribofilaments?

The dimensions of the filament spools can be viewed on the product pages in the shop. 

How do you get filaments to adhere to the printing plate?

For the tribofilaments, igus offers the adhesion promoter for tribofilaments and the adhesive films, which can be ordered in the shop. The adhesion promoter is applied as a liquid to a printing surface (such as glass) and serves as an adhesion medium and release aid when the plate has cooled down. The film is glued onto the printing plate and provides improved adhesion. The adhesion promoter is the only one suitable for Ultimaker 3D printers.

For which 3D printers and filaments are print profiles available?

We offer print profiles for the iglidur i150, i151, i190 tribofilaments for processing on the 3D printers Bambu Lab X1C and Prusa MK3/MK4. However, for Bambu Lab X1C the print profile for iglidur i180 is also available. In addition, profiles for iglidur i180, i150 and i190 are also available for some Ultimaker 3D printers (Ultimaker S3, S5 and S7). You can find an overview of all available print profiles and the respective processing instructions here.

The print profiles for Ultimaker Cura do not work, what can I do?

The profiles for iglidur i150, i180 and i190 can be installed in Cura via the Marketplace. The software must then be restarted. The profiles only work for Ultimaker 3D printers (S3, S5, S7) and the materials can be selected only if such a device is set up in Cura. No profiles for other 3D printers are available for download in Cura.

Is there a fibre-reinforced filament from igus?

igumid P150 and igumid P190 are carbon fibre-reinforced filament materials that have a much higher stiffness and strength than the tribofilaments.

Do igus filaments need to be dried?
Drying filaments is generally recommended from time to time to ensure high surface quality and optimum mechanical properties and material printability. Some filaments should be dried more frequently, e.g. iglidur i190, iglidur A350 and iglidur RW370. The filament spools can be dried in a standard household convection oven or in a dry air oven designed specifically for this purpose. Further processing instructions can be found in the download area on the product page of the respective material in the shop.

What is the maximum drying temperature?

The rule of thumb is a drying temperature that does not exceed the maximum application temperature of the plastic, but also does not damage the plastic spool. For filaments on matte black plastic spools max. 70°C, on transparent spools max. 90°C and on glossy black spools (high-temperature filaments) max. 125°C with a minimum drying time of 4-6 hours. Further processing instructions can be found in the download area on the product page of the respective material in the shop.

What material is suitable as a support material for tribofilaments?

Depending on the tribofilament, various soluble filaments, including water-soluble ones, such as PVA, from various third-party suppliers can be used. For filaments such as iglidur i180, i190 and J260 with a higher processing temperature, a suitable support material for higher temperatures should be used if necessary (e.g. Formfutura Helios). An alternative is the so-called "Breakaway" support materials that can be easily removed by hand after 3D printing. For some tribofilaments, e.g. iglidur i150, PLA is also suitable as a support material, which can be removed manually without much effort after printing. We can make no recommendation for the high-temperature tribofilaments (iglidur RW370, A350, etc.) at the moment. Further processing instructions can be found in the download area on the product page of the respective material in the shop.​

Which filament 3D printer does igus recommend?

Due to the large number of systems available on the market, no clear recommendation can be made. Basically, the printer should have a sufficiently large and closed build chamber as well as a heated print bed. In addition, a print head with two nozzles or two independent print heads that can heat up to 300°C, are recommended. The device should also be freely configurable, i.e. the processing parameters should be adjustable and the processing of filaments from third-party manufacturers should be possible. Other useful specifications include interchangeable magnetic plates, network connectivity, direct drive extruder and automatic print bed levelling. You should be able to process our filaments on most common printers without any problems. We shall also be happy to send you material samples if you have purchased a printer - you are welcome to contact us.

Which materials can be combined?

Some filaments can form a material compound due to their molecular composition. Many others cannot be easily combined with each other, so that a form-fit connection should be constructed here. For more information, see our blog post on multi-material printing.

More about our filament range in the shop.

Can the igus printing materials be milled or otherwise mechanically processed?

Appropriate mechanical rework is possible. The usual measures for unfilled plastics (e.g. POM) apply to machining on the lathe. A holder may have to be produced here to prevent deformation of the component during clamping. Due to the increased wear resistance of the iglidur materials, grinding is more demanding than with standard plastics.

Are there resins for the SLA/DLP process from igus?

Yes, igus has developed a tribologically optimised 3D printing resin for processing on DLP and LCD printers. It is particularly well suited to manufacturing very small components with fine details and smooth surfaces. Wear-resistant parts made from this resin can be ordered in the 3D printing service. The material is also available in the igus online shop.

What material is the best choice for housings?

Producing such parts with the igus service may be more expensive than with other service providers, since igus uses materials specially optimised for minimum friction and wear. iglidur i8-ESD is a good choice because of its colour and antistatic specifications and igumid P150 or P190 because of its fibre reinforcement.

Are there conductive 3D printing materials from igus?

Yes and no. Modified plastics have a very high resistance compared to metals. iglidur i8-ESD has a specific resistance of approx. 1 x 10^7 ohm x cm in the range of "antistatically dissipative", but not really conductive. The new iglidur i9-ESD has a higher resistance of approx. 1 x 10^9 ohm x cm. You can find out more about the two products in the shop.

Are there fire-retardant 3D printing materials from igus?

The tribofilaments iglidur RW370 and A350 are fire-retardant according to UL94 V-0. iglidur RW370 also complies with the EN45545 standard for railway vehicles. The laser sintering material iglidur i3 meets the standard FMV SS 302 or DIN 75200 for vehicle interiors. The certificates can be downloaded under the "Downloads" tab on the product pages in the shop.

Are there FDA-compliant 3D printing materials from igus?

The laser sintering materials iglidur i6 and iglidur i10 as well as the tribofilaments iglidur i151 and A350 are approved for food contact according to FDA and EU 10/2011. The certificates can be downloaded under the "Downloads" tab on the product pages in the shop.

What material is suitable for use under water?

Tests with iglidur materials in rotating and pivoting applications under water have shown that the iglidur i8-ESD laser sintering material is especially well suited to such environmental conditions because the wear rate in this environment is very low.

What material is UV-resistant?

In the weathering test (8 hours irradiation with UV-A as well as 4 hours of condensation at 50°C for a total of 2000h / ASTM G154 Cycle 4), the laser sintering material iglidur i8-ESD showed a change in flexural strength of only around -9% with long-term resistance to weathering effects such as UV radiation. The laser sintering material iglidur i3 shows a change in flexural strength of approx. -14% and can therefore also be classified as resistant to weathering effects.

What is the chemical resistance of the iglidur 3D printing materials?

The chemical resistance of the tribofilaments and laser sintering materials can be viewed in the searchable lists in the "Technical data" tab on the product pages in the shop or for the materials under "More information" in the iglidur Designer.

Find out more on the Materials page.

Which iglidur laser sintering material is best suited for gears?

iglidur i3 has the longest service life of all igus 3D printing materials in tests with spur gears. For worm gears, iglidur i6 is better suited due to the relative sliding movement between the mating partners.

What filament is best suited for gears?

The best results in the service life comparison of the tribofilaments as well as some standard 3D printing filaments are achieved by iglidur i190 and igumid P150. No detailed report is currently available, but one is planned for the future.

What tolerance or precision level is achieved when plastic gears are manufactured with the laser sintering process?

To determine the tolerance, you must take the dimensions of your component into account. Parts up to 50mm have a tolerance of ± 0.1mm. Parts larger than 50mm have a tolerance of ± 0.2%. These values apply to non-reworked parts.

Can metal gears be replaced by 3D-printed gears made of iglidur?

Metallic gears can withstand higher loads than plastic gears. If you have a metal gear that is reaching the limits of what a metal gear can do, you cannot replace it with a plastic gear. That would require a gear three or four times the current size. But if the metallic gear is not at the limit of what metallic material can do, you can, of course, replace it with a polymer gear, and then you have a system that requires no external lubrication and for which you can receive any type of gear very quickly. You can use our service life calculator to check whether this is the case for your application.

Does the gear service life calculator work with small gears (with 12 teeth, for example)?

Our calculation tool works only from 17 teeth. Less than 17 teeth would require undercut information for the calculation, and our calculator has no option for adding or using it. If you need a gear with fewer than 17 teeth, get in touch with your igus contact.

Can teeth be adjusted (profile adjustment)?

We can print parts for which the teeth have been adjusted. This is not currently reflected in our configurator. If you need such gears and have no capability for designing them, don't hesitate to contact us.

With regard to the tests in the igus test laboratory, the 5Nm act tangentially on the tooth?

The 5Nm act on the entire gear, not on the teeth.

Is there a tool for generating the gear/tooth geometry (input module, number of teeth)?

You can create your gear with the help of our gear configurator.

How do I get gears with a low number of teeth, e.g. ten teeth?

With the extension of our gear configurator, it is now possible to configure gears from eight teeth.

Are gears made from iglidur 3D printing filaments suitable only for prototypes or do they perform well enough to be used as functional parts?

iglidur tribofilaments are more suitable for bearings and other wear-resistant parts. Gears made from our laser sintering powders, on the other hand, have a much longer service life than those made from our filaments.

Is there a minimum size limit for 3D printed gears?

Our minimum wall thickness is approx. 0.7mm. If we need to, we can go as low as 0.5mm, but we normally recommend a minimum of 0.7mm.

Is there test data about wear that compares 3D igus gears to other machined plastic gears?

Yes. The results of the wear test can be found here.

How can gear materials be combined in the best way?

You can make both gears out of plastic and use our service life calculator to determine the point at which the system stops functioning well. There will be a point at which polymer gears no longer function well because the load is too high.

Are the printed gears solidly built?

At igus, we always print all parts solid, so they are 100% plastic and can be reworked. We produce solid parts because they are used as gears, bearings and whatever else in machines, and must therefore have the highest possible stability. You can, of course, also design lightweight components to reduce weight. If that is what you want, let us know, and then we won't print solid gears.

Do you need a special 3D printer to produce food-safe components?

Before and during printing, the food-grade material must be protected from dust. We therefore recommend an enclosed build chamber.

Does the printer have to be specially cleaned before printing with food-grade materials?

Basically, all parts that come into contact with the filament should be free of residues. This applies in particular to the extruder sprocket and the pressure nozzle. In addition, a clean print bed is imperative. The glass plate should be cleaned and the use of either no adhesive or a food grade adhesive is recommended.

What do I need to bear in mind with the print settings?

The settings should be selected in the slicing software so that the surface of the object is as dense as possible. Among other things, this is achieved by lowering the printing speed and adapting the line width to the nozzle diameter. This allows unevenness in the component surface and reduces gaps in the cover layers.

Can I also achieve food safety for the component with two materials in multi-material printing?

It is not recommended to produce food grade components in multi-material printing together with other, non-food grade materials, as mixing of the materials cannot be completely ruled out. The support material should either be food grade or the same material should be used as support material.

Do 3D-printed parts require an additional food-safe coating?

Components printed with food-compatible iglidur materials have a food-safe surface, so no additional coating is necessary. This applies to the 3D printing materials iglidur i150, iglidur i151  and iglidur A350.

Are printed machine parts automatically food-safe if food-grade material is used for printing?

No, you only achieve food conformity by combining it with a clean 3D printing process. It is important to use clean print nozzles, for example, for the 3D printing of food-safe components. In addition, either no adhesive (glue) or a food-grade adhesive should be used.

Can a printed component that complies with food regulations come into permanent contact with food?

If there is prolonged contact between the plastic component and food, this increases the chance of migration of plastic particles. Therefore, it is important to check the food compliance declaration for the maximum permitted contact time. This can vary depending on whether you consider the FDA or the EU 10/2011 declaration. The ambient temperature of the application also plays a role here. The higher the temperatures, the shorter the contact should be.

Order your food-safe component now from the 3D printing service.