Drive and conveyor manufacturer Tsubaki Kabelschlepp has integrated 3D printing and scanning tools to increase the efficiency of its cable carrier development process.
Cable carriers are central components for the reliable guiding of energy and data cables in dynamic applications such as crane systems, conveyor systems, robotics and automated storage systems.
Integrating additive manufacturing technologies into the design process of these components has enabled Tsubaki to reduce development times, save materials and implement customised solutions in an economically viable manner.
The increasing level of automation is a rising challenge in the field of intralogistics. More data must be transferred, and therefore more cables are needed that require reliable management. At the same time, the requirements for variant diversity, installation space integration and service life of the cable carrier are increasing. This means that development processes must become faster, more flexible and more economical.
To meet this demand, Tsubaki is using 3D printing and scanning tools within its product development process. Printed prototypes can be tested mechanically during early stages of the process, then trialled in the installation phase. The technology allows designs to be optimised without cost-intensive tool changes, which decreases iteration loops and reduces material usage by up to 80%.
Tsubaki uses selective laser sintering (SLS), an established and robust process for industrial prototyping and small-batch production. The dimensional tolerances are in the range of ±0.2 mm plus a percentage of the part length. Parts printed via SLS require no supporting structures, which makes it possible to produce complex geometries without additional steps. This opens up new flexibilities for designing cable carriers in terms of integrated functions or geometrically optimised parts.
The company is currently using additive manufacturing for functional tests, small-batch runs and customised components. The technology is structured as a container solution and managed like an injection moulding machine, including a connection to existing production and ERP structures. This ensures predictable processes, high quality and complete traceability.
For intralogistics applications, this approach offers quick availability of samples and reduced project risks. The technology still remains a supplementary process at Tsubaki, however, with defined limits in terms of material variety and surface quality.
“In our concept, the manufacturing process follows the task at hand,” said Peter Pütz, vice president marketing and innovation at Tsuabki Kabelschlepp. “If additive manufacturing is the best solution, we use it. If injection moulding is the superior choice, we use that. And if both together offer the best solution, we combine them.”
