Novel Rapid Prototyping processes -: Building movable parts

Each year more than 100 new or enhanced systems for different applications are entering the market. More and more mechanical solutions are replaced by electromechanical or mechatronic solutions. Due to these new mechatronic systems required also new solutions concerning the design, development and implementation of mechanical and electrical parts are required. First the development of a rapid prototyping process allowing parts moving or sliding towards each other after finishing the process is crucial. Assembly and mounting of components is not any longer necessary. Especially the 3D-Printing process is one of the candidates to solve this problem using sacrificial layers between the moving parts. Second the functional parts have to cover the possibility of testing and reliability investigations. Due to this direct implementation of electronic components during rapid processes is necessary. A strategy will be shown concerning the implementation of mechanical as well as electrical parts. Examples of rapid processed mechatronic parts will show the potential of these solutions. Especially for SME these novel production possibilities could be very important. In this paper first result of a project concerning "Novel rapid processes building movable parts" and packaging processes of micro-electronics are presented. The presentation will show a comparison of the conventional technology and the new packaging technologies concerning movable parts like gear wheels. Additional focus will be given to the direct implementation of electronic components and systems using rapid processes like stereo lithography and 3D-printing. An overview of the demands for new rapid materials and their application will round up the presentation.