Product development: Threaded plugs

Customised small series from the 3D printer

Special requirements and a low quantity were the challenge when it came an enquiry for threaded plugs. Thanks to 3D printing, a short term and cost-effective manufacturing of the small series was possible.

Initial situation: Solution needed for threaded plugs

Following a series of different post-processing steps on a high-pressure connection, a customer approached Würth Industrie Service with a request of manufacturing special threaded plugs (M38x1.5). The task was to prevent impurities in the interior of the high-pressure connection and the attached high pressure pump. The required quantity was 30 pieces.

Additive manufacturing of threaded plugs

Additive manufacturing fulfils quality and economic requirements.

As the interplay between the fine threads and the specified thread length posed a challenge and the requested quantity was low, the possibilities of additive manufacturing came into the focus for the experts at Würth Industrie Service.

In the course of the collaborative project, the customer’s wishes were individually implemented when designing the threaded plug. The threaded plug was optimised consistently over the prepared CAD-model and the technical drawing after consultations with the customer until it matched their expectations.

The required quantity could subsequently be additively manufactured, packaged and sent to the customer within a day.

Series production with injection moulding

Since the demand for the individual stopper from the customer increased enormously, the stopper is now produced as a series using the injection moulding process. Due to the larger quantity requested, the conventional process is the more economical alternative. Würth Industrie Service continues to take care of the production and logistical provision.

Factors of success - Success Story

Factors of success

In the above mentioned example, additive manufacturing has significant advantages given the customisation and low production quantities over conventional procedures like injection moulding or subtractive procedures. The tool costs alone for injection moulding would have exceeded the value of the required quantity in comparison to additive manufacturing. Besides, the production and delivery times would have been significantly higher.

Through the continuous profitability check of Würth Industrie Service, the injection moulding process proved to be the more cost-effective option after a certain quantity of enquiries had been reached.

Additional information

Würth Additive Manufacturing
CPS®WAM - Würth Additive Manufacturing
Topology optimisation
Component optimisation with additive manufacturing technologies
Product development with the help of 3D printing
Customised product development with the help of 3D printing
Spare parts manufacturing using 3D printing
Easy spare part supply using 3D printing