Plastic Pipes Conference Association # 2023 Lake Buena Vista
Ton Schoenmaker
For years the way of producing a flow profile for Inspection Chambers and Manholes could be divided into 3 methods: Injection moulding, Roto moulding and Hand assembling. For the standard orientations, for example straight through and cross, the IM profile integrated with a base is by far the best option. But for nonstandard configurations; different orientations, inlet heights and inlet sizes, the only option is to hand weld them together from injection moulded parts, pipes and plates. This is a time-consuming way of producing with high production cost and often aesthetic-wise of a challenging level. This is not necessary anymore after the introduction of 3D printing as a new production method for flow profiles in chambers and manholes.
3D printing is in many industries an accepted production method which can produce parts of high quality and high accuracy. The printing systems have faced a huge development in the last 10 years and prints are often close to perfection. The only disadvantage of these printing systems is the maximum size of the print. But since the introduction of 3D robot printing, products with a diameter of 1 meter can be printed without any problem. 3D robot printers were up to recently, used for prototypes, one-off products and art objects. Now a production area is created on which multiple products can be produced in a row without human interference.
The most common materials used for 3D printing are ABS and PLA. These materials have good adhesion, almost no shrinkage and a good appearance. Unfortunately, these materials are not common in our industry. We need PP, PE or PVC.
While our manholes and inspection chambers are from PP we also need PP flow profiles. The advantage of using a 3D robot printer is that it uses granulates instead of filaments or special powder. This makes the material cost part almost equal to injection moulding. Another advantage is also that recycled material can be used. Own scrap can be used but also waste from other markets. The main reason that flow profiles are ideal for 3D printing is that nonstandard flow profiles are very labour-intensive. So 3D printing really helps out here. Besides that, there is a lot of freedom in design. This helps to design in such a way, that the final profile is hydraulically optimal. This prevents the overflowing of manholes during heavy rain showers.
Of course, these products should fulfil all requirements of the EN13598-2. Even though major development steps have been made in 3D printing during the last 5 years, 3D robot printing is still in the exploring phase and we find many hurdles on our way. This paper will show how our industry can use 3D printing and what are the pros and cons.
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