A prototype of a noise barrier with photovoltaic modules for generating power along highways

Prototypes and functional models are increasingly being created using 3D printing to get an initial impression of how dimensions can be improved or simplified.

Manufacturing profiles using the SLS process may seem a little unconventional, as the FDM process entails lower material costs. The prototypes had to be bondable, robust and coatable without pre-treatment, however, so SLS 3D printing was used.

Four iterations of the profiles were printed in order to achieve optimal results. The molded contours and design of the profiles both played a part in the extrusion process. The contour radii, internal reinforcement ribs and strength-related parameters all had to be taken into account so that the profiles would interact as effectively as possible when deployed in the photovoltaic substructure.

In the specific case of the noise barrier, the cable ducts and various sealing strips that were subsequently inserted were the subject of particular attention. Even configurations that appear simple, such as profiles, often represent complicated systems that have to be coordinated effectively in order to offer custom solutions.

The metric screws used in the assembly were also scaled for the prototype and screwed in directly using a thread, to ensure that they would function in the final application. The option of integrating the hexagon socket screws into the 3D-printed version using the TIGITAL^® 3D set was given due consideration and was deemed viable. Precisely fitting holes and cut-outs for feeding through the cable were also executed for the prototype.

The main advantage of this prototype is that it represents a realistic model, albeit scaled from its original size to an edge length of about 5m and a height of about 3m. Production of the extruded profiles can commence immediately, so this approach offers significant advantages:

• Reduced time to market
• Early optimization of component dimensions for production
• Consideration of customer requirements regarding final assembly

As powder coatings cannot be applied to 3D-printed parts made of polyamides, due to their heat resistance, customers often have to switch to wet coatings. In addition to potential issues with adhesion problems, using polyamides can also lead to annoying variations in color.

Working with TIGITAL^® 3D Set has opened up numerous other synergies due to our many years of expertise in powder coating with high-quality TIGER Drylac^® coating solutions and printing with TIGITAL^® Inks & Tattoo (digital inks and powder for industrial printing systems).

Opportunities abound for improving the visual appearance of prototypes and finished extruded profiles by powder coating and printing. The final products, which are manufactured from steel or aluminum profiles on the basis of the 3D-printed model, can be finished with TIGER Drylac^® for the best possible protection against corrosion and weather effects.