RadioKraków, a Polish radio station, has a tape recorder that has been in use for many years, but its parts have worn down and become unusable. This NAGRA Ares-M recorder is a model from over a decade ago, but it is still in service; whether used for recording radio, movies, or other purposes, it always provides high-quality sound. However, any device will wear down after thousands of uses under stress and in various environments, and the weakest point is the frequently opened and closed battery cover.
The friction and stress generated by the frequent opening and closing of the battery cover can cause the part to break. In this case, the plastic cover usually starts to fail at the contact point where the thickness is uneven. When using plastic injection molding, even a thickness error of a few tenths of a millimeter can cause internal tension in the material, which will cause the product to cool unevenly and crack again at the contact point, which is not the desired result.
Before using Sinterit Lisa to print the new casing, repair personnel frequently had to use glue to secure the recorder, a repetitive, time-consuming, and inefficient process. To overcome this problem, they redesigned the battery cover and manufactured it using 3D printing , which not only secures it to the recorder but is also more durable than the original structure. The designers first measured the original battery cover, created a 3D model, and printed it out, then made modifications based on prototype testing.
While the newly designed cover, based on the initial measurements, was fully functional, the designers decided to improve some details because even a 0.1mm difference in the latch structure could affect the durability of the 3D printed product. The revised casing surface was better than the original, and the company name "RadioKraków" could even be conveniently marked on the recorder to prevent loss.
The high precision required for the latch structure on the battery cover makes SLS technology and PA12 Smooth powder the optimal choice. Furthermore, SLS 3D printing maximizes both build time and the number of prototype modifications, allowing all versions requiring testing and modification to be placed within a limited print space. All design variables can be tested immediately after a single print run, a characteristic of SLS printing that results in shorter production times for the optimal design version compared to other technologies. (Further reading: Comparison and summary of 3 common 3D printing technologies )
This practice has already helped the radio station save money and time, eliminating the need to repurchase and train staff to use new recording equipment due to minor parts damage. Sinterit Lisa currently has numerous application cases across various industries; please refer to our other articles for more information. If you need parts made, we also offer high-quality printing services using original 3D printers , ensuring you achieve the same high-quality results.
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