Revolutionizing Custom Control Systems: IBL Hydronic’s Success with Formlabs SLS 3D Printing

In the dynamic landscape of modern manufacturing, the benefits of advanced technologies like 3D printing are increasingly recognized, particularly for their ability to deliver unparalleled customization and cost-effective production for small to medium batch sizes. This transformative potential has been demonstrably realized by Germany-based IBL Hydronic, a company at the forefront of developing sophisticated control systems for diverse applications, including specialized machines and vehicles. To meet their stringent requirements for bespoke solutions, IBL Hydronic has strategically adopted Selective Laser Sintering (SLS) technology, leveraging the robust and efficient Formlabs Fuse 1 ecosystem.

Established in 1987 by Dr.-Ing Thomas Löcher, IBL Hydronic has built a formidable reputation for crafting innovative custom electronic, hydraulic, and software solutions. Their expertise spans across a multitude of sectors, including but not limited to, construction, agriculture and forestry, as well as the specialized machine and vehicle industries. A core tenet of IBL Hydronic’s operational philosophy is the in-house production of their components, coupled with an unwavering focus on addressing the unique individual challenges and needs of each client. This commitment drives them to develop highly specific, tailored solutions. Given these foundational principles, the integration of 3D printing, specifically through Formlabs’ acclaimed Fuse 1 SLS 3D printer, presented itself as the optimal manufacturing solution, perfectly aligning with their bespoke production model.

IBL Hydronic is not alone in reaping the significant benefits of Formlabs’ pioneering additive manufacturing technology. In recent years, Formlabs has consistently pushed the boundaries of innovation across its Selective Laser Sintering (SLS) and Stereolithography (SLA) solutions, thereby expanding their applicability across an even broader spectrum of industries and use cases. This continuous evolution will be prominently showcased at Formnext 2022, Europe’s premier additive manufacturing conference. Formlabs will demonstrate its latest advancements, including the cutting-edge Fuse 1+ 30W, among other products, at their dedicated booth (Hall 11.1, Booth E11). Visitors will have the unique opportunity to examine parts from leading industry partners, including those from IBL Hydronic, providing tangible evidence of the technology’s capabilities. We delve deeper into how SLS 3D printing is ingeniously employed for both high-fidelity functional prototypes and intricate hydraulic end-use components, exploring what else attendees can anticipate from Formlabs at this year’s highly anticipated event.

Leveraging SLS 3D Printing for Custom, Automated Control Systems

The turning point for IBL Hydronic arrived when they recognized that their existing conventional production processes had reached their inherent structural and design limitations. This critical realization prompted them to seriously consider whether 3D printing could offer a viable and superior alternative. The impetus for this exploration was particularly strong given the company’s business model, which, similar to many in their industry, involves producing vehicles and specialized equipment in small to medium batches, typically ranging from 100 to 250 parts. For such quantities, traditional manufacturing methods, most notably injection molding, necessitate substantial upfront investments in tooling. This makes the prospect of investing in extensive fleets of in-house production equipment for traditional processes prohibitively costly and economically unfeasible for custom, low-volume runs.

Following a thorough evaluation and experimentation with various 3D printing technologies, IBL Hydronic made a strategic investment in a Fuse 1 SLS 3D printer from Formlabs in 2019. This decision marked a significant pivot in their manufacturing strategy. Since that pivotal acquisition, the company has consistently expanded its in-house 3D printing operations to efficiently meet the escalating demands for their highly customized components. Tom Heindl, the technical product designer for 3D printing at IBL Hydronic, underscores the profound impact of this transition: “Having an SLS 3D printer means that we simply no longer have to use manufacturing methods such as CNC milling, turning, or machining. This of course saves us a lot of time, money, and also space.” He further elaborates on the specific appeal of SLS 3D printing, highlighting its unique capability to print parts without the need for cumbersome support structures. This inherent advantage dramatically expands design freedom, opening up possibilities for even more complex and valuable projects that were previously unattainable or economically prohibitive with conventional methods.

Today, 3D printing has evolved from a supplementary tool to an indispensable core element in IBL Hydronic’s process of creating bespoke solutions. The adoption of additive manufacturing has yielded a multitude of tangible benefits for the team. Foremost among these advantages are the exceptional speed and unparalleled flexibility offered by the technology. These attributes are foundational to the accelerated development processes for new control modules, enabling even significant design modifications to be implemented with remarkable swiftness. Consequently, IBL Hydronic can produce high-quality functional prototypes in an astonishingly short timeframe, often within just two to three weeks. This agility allows them to respond to market demands and customer feedback with unprecedented efficiency. Furthermore, this technology empowers them to concentrate on the precise needs of their customers at a level previously unattainable, thereby establishing a distinctive competitive edge and unique selling point within their specialized market. The company also consistently points to the ease of use of Formlabs systems and, crucially, the significantly more cost-effective production of individual and small-batch parts compared to traditional methods.

The transformative impact and vital importance of SLS 3D printing for IBL Hydronic are vividly illustrated by the resounding success of their latest project: the development of a highly specialized control panel for a prominent agricultural machinery manufacturer. This particular project demanded a control panel meticulously tailored to the unique specifications of a specific machine model. Not only was the project brought to fruition in record time, with the complete control module ready for presentation after an impressive single month, but SLS 3D printing also facilitated the creation of a design that was both highly functional and aesthetically captivating. The ability to integrate intricate textures, mimicking high-quality leather, further enhanced its visual appeal, making it virtually indistinguishable from conventionally manufactured components. Buoyed by these successes, IBL Hydronic is optimistic about their trajectory, anticipating continued scaling of their operations and a broadening of their innovative horizons. Heindl’s concluding remarks powerfully encapsulate this sentiment: “If we hadn’t invested in our in-house 3D printers and learned the process, we wouldn’t have gained certain customers.” This statement underscores the critical role of additive manufacturing in securing new business and fostering client relationships in a highly competitive market.

Discover More About the Benefits of SLS at Formnext 2022

While the compelling case of IBL Hydronic serves as a powerful testament, it represents just one of numerous innovative applications successfully achieved through the sophisticated capabilities of Formlabs’ SLS and SLA 3D printing solutions. For industry professionals, innovators, and enthusiasts keen on delving deeper into these cutting-edge technologies, Formlabs is set to showcase an extensive array of application cases featuring diverse users at their dedicated exhibit. Located at Booth E11 in Hall 11.1 at Formnext, the Formlabs booth promises a comprehensive experience. Alongside the impressive contributions from IBL Hydronic, attendees will have the opportunity to explore compelling examples from other esteemed customers, including Vital Auto, XSpecter, and Deutsche Bahn. These case studies will collectively highlight the versatility, reliability, and transformative power of Formlabs’ additive manufacturing ecosystem across various sectors, from automotive and consumer goods to industrial and transportation applications.

Adding to the excitement, Formlabs is poised to unveil a groundbreaking new solution at the highly anticipated Formnext show. The Fuse 1+ 30W, the much-anticipated successor to the acclaimed Fuse 1 and the latest addition to Formlabs’ pioneering SLS series, will be prominently displayed. This advanced machine will be presented alongside other cornerstone products in their ecosystem, including the Form 3+, Form 3B+, Form Wash, Form Cure, the large-format Form 3L, Form 3BL, and an impressive portfolio of over 40 high-performance materials. The Fuse 1+ 30W is particularly noteworthy and generates considerable excitement within the industry because, as Formlabs highlights, it boasts the capability to print parts up to two times faster than its previous generation. This significant speed enhancement dramatically boosts throughput and efficiency. Moreover, its advanced architecture has unlocked the potential for utilizing a new range of cutting-edge, high-performance materials, further expanding the applications and capabilities for users seeking robust and innovative solutions.

For those with a keen interest in exploring Formlabs’ innovative offerings further and experiencing the future of additive manufacturing firsthand, a unique opportunity awaits. You can secure a voucher for an exclusive 50% discount on your Formnext event ticket directly from Formlabs by clicking HERE. Additionally, to maximize your experience and gain personalized insights, you can pre-book a dedicated slot at the Formlabs booth with one of their expert specialists. To schedule your individual consultation, please click HERE. Don’t miss this chance to engage with industry leaders and discover how Formlabs is shaping the future of industrial production.

What are your thoughts on the increasing adoption of SLS 3D printing for specialized small and medium custom batches? Are you eager to discover more about Formlabs’ latest innovations and applications at Formnext 2022? We encourage you to share your insights and engage in the conversation by leaving a comment below, or by connecting with us on our LinkedIn, Facebook, and Twitter pages! For the very latest news and updates from the world of 3D printing delivered directly to your inbox, don’t forget to sign up for our free weekly Newsletter here. You can also explore all our insightful videos and content on our dedicated YouTube channel.

*Cover Photo Credits: Formlabs