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You are here: Home / Linear Motion / Actuators / Leadscrews lead in 3D printing, manufacturing, and medical designs

Leadscrews lead in 3D printing, manufacturing, and medical designs

March 4, 2015 By Lisa Eitel Leave a Comment

1-Haydon-Kerk-Micro-Series-Screws
These Micro-Series leadscrew assemblies from Haydon Kerk Motion Solutions are micro-sized 303 stainless-steel leadscrews with 2-mm diameters and leads from 0.3 to 2 mm per revolution. Nut configurations include those made of self-lubricating acetal and Kerkite composite polymers, including nylon, PPS and PEEK. The leadscrews come as stand-alone components or integrated into Haydon linear actuators. An optional Kerkote TFE coating (a dry lubricant) extends nut life while reducing friction and drive torque requirements.

Leadscrews are a staple of motion designs, driving axes on machines big and small. They usually sport higher ratings than comparable ballscrews thanks to more contact between the nut and screw load surfaces. Now, innovations in materials and helix geometry address old issues associated with leadscrew friction, bringing it down to better than 0.10 in some cases—good for fast and dynamic applications. In fact, there’s also been an uptick in leadscrew use because of proliferating machines for 3D printing, manufacturing and medical applications that didn’t exist 10 years ago.

“We’ve seen advances in technology at the component and system level,” said Mark Huebner, market development manager at PBC Linear. “For example, constant-force anti-backlash nuts and leadscrews have given us two to four times better accuracy control while extending useable life by as much as fivefold. We’re also seeing more use of our self-lubricating linear bearings in sanitary and washdown applications, where they resist corrosion.”

2-lead-screws-Thomson-motorized
These motorized leadscrews from Thomson Industries include a hybrid stepper motor and leadscrew for up to 30% more load capacity than comparable actuators. Traditional leadscrews with direct couplings are permanently attached to the motor, making them difficult to replace and maintain. In contrast, taper locks on these motorized leadscrews let users quickly connect and connect the motor—useful for prototyping or maintenance. Rotating screw and rotating nut versions deliver up to 200 lb for medical pumps, HVAC control valves, pipetting machines, and CNC applications.

In systems innovations, PBC Linear sees engineers and designers leveraging the advantages of complete packages—pre-engineered alignment built into integrated linear-rail-raceway combinations, for example. “This eliminates the tedious and expensive task of installing and aligning individual shafts or rails while also cutting down the number of components and associated costs,” said Huebner. The same principle applies to integrated stepper-motor-and-leadscrew designs, which eliminate the coupler, mounting bracket, and more for rigidity and accuracy with fewer components, Huebner added. The trend of integrating smart motors also continues—so users can connect to myriad networks while simplifying installation and wire-and-cable management.

Trends in new leadscrew uses

Industries across the board are adopting new leadscrew components and linear systems, but some are leading the charge. Designers of kiosk and automated retail applications are always looking for ways to simplify machines, reduce design weight and simplify assembly and maintenance, according to Huebner. That is where designs with pre-engineered alignment and integrated rails excel.

In a similar way, both additive manufacturing (3D printing) and traditional subtractive processes—plasma cutter, laser and waterjet manufacturing—are driving new leadscrew uses. The same holds true for factory automation. “The move to integrated systems, especially those with smart

3-Xinray-Aurora-RepRap-3D-printer-with-leadscrews
This maker-grade 3D printer is a RepRap Aurora built by XinRay with leadscrews for two of the axes. 3D printing is one of several applications making new use of leadscrew technology.

motors, is giving machines higher control and accuracy, so builders can bring better products to market,” said Huebner.

He added that as 3D printing has become popular in the last 10 years, engineers have wanted to print larger and larger parts … but the linear motion required to do so accurately has been cost prohibitive. “To address this issue, 3D-printer builder 3DP Unlimited has taken our leadscrew-based actuators and integrated linear-motion platform and integrated them into a large-format 3D printer just under $20,000. The build platform is 1 x 1 x 0.5 meters and would not have been possible 10 years ago at such a low price point,” said Huebner. It leverages pre-engineered rail alignment, constant-force anti-backlash leadscrews, and motors with outboard amplifiers that simplify wiring and boost heat dissipation.

Another trend is that more OEM designers and end users are looking to buy pre-engineered linear slides and guides. Several things are behind this trend. “We see this fit with our design on a diet philosophy—the idea that newer

4-3dpUnlimited-PBC-Linear-leadscrews
This industrial-grade 3D printer from 3DP Unlimited is the X1000. It incorporates SIMO Series linear actuators from PBC Linear over a 1 x 1 x 0.5-meter workspace. It’s based on open-source controls and starts at $15,999.

components, integrated design elements and features, and complete solutions bring lower installed cost, enhanced performance, and faster time to market for engineers freed to focus on their core competency and process development,” PBC Linear’s Huebner said.

Filed Under: Actuators, Industry News, Linear Motion Tagged With: pbc linear

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