Summary
The electrical equipment industry faces significant challenges in rapid prototyping due to high costs and extended lead times of traditional metal tooling for epoxy resin casting. This study systematically evaluates three additive manufacturing technologies (vat photopolymerization, selective laser sintering, and binder jetting sand printing) as alternatives for producing reusable moulds for vacuum casting of electrical insulation components. The research employs laboratory-scale characterization and industrial validation using medium-voltage current transformers. Surface roughness, dimensional accuracy, mould durability, and electrical performance were assessed. Results demonstrate that vat photopolymerization moulds deliver superior surface quality (Ra = 0.4÷0.9 µm) and durability (>12 cycles) at premium cost.
Read more Read lessSelective laser sintering provides optimal cost-performance balance with excellent surface finish after vapor smoothing (Ra = 1.1÷1.5 µm), good dimensional accuracy, and 8-10 cycle durability. Binder jetting sand moulds offer lowest cost and fastest lead time (1-2 days) but limited quality and durability (3-5 cycles). All current transformers casted in 3D printed moulds passed partial discharge testing. Economic analysis reveals even 30 times cost reduction and 10 times faster lead times versus traditional tooling. These findings validate additive manufacturing for prototyping and small-series production in the electrification sector.
Additional informations
| Publication type | Session Materials |
|---|---|
| Reference | D1_11202_2026 |
| Publication year | |
| Publisher | CIGRE |
| Country | Poland |
| Study committees | |
| File size | 1 MB |
| Price for non member | 30 € |
| Price for member | 30 € |
Authors
RYBAK Andrzej - ABB Corporate Technology Center Poland; SIWEK Artur - ABB Corporate Technology Center Poland; JAVORA Radek - ABB s.r.o. Czech Republic
Keywords
Additive Manufacturing - Rapid Tooling - Fast Prototyping - Epoxy Casting
