Polyamide PA6 boxes for complex automotive components
Automotive · Transport & Storage Boxes · FDM · PA-CNF Materials
Rapidobject developed custom transport and storage boxes for sensitive components and battery cells for an automotive OEM.
By using innovative, cotton-fiber-reinforced polyamide materials in the FDM process, the company was able to create a functional, cost-effective, and design-flexible solution.
Initial situation
The customer needed special boxes for the separate storage and safe transport of various components within the production and analysis process.
The complex inner contours of the boxes posed a particular challenge, as they could not be produced cost-effectively using conventional manufacturing methods such as milling.
Originally, the plan was to manufacture them from ABS.
Challenge
In addition to the complex geometry, there were other requirements that had to be met:
- small quantities and a wide variety of options
- Clear color coding to prevent mix-ups
- high mechanical strength combined with low weight
- Suitable for cleanrooms and sensitive components
Conventional manufacturing processes would have resulted in high costs and limited design flexibility.
The goal was to develop a total of six boxes in various sizes and colors. The boxes were to be functional, durable, easy to clean, and cost-effective to manufacture.
Our Solution
Rapidobject relied on the FDM process in combination with a novel cotton-fiber-reinforced polyamide material (PA6 CNF DX).
Several design improvements have been implemented:
- side insertion of the threaded nuts without interrupting the printing process
- Integration of melting bushings
- Adjustment of the die pockets to ensure process reliability
The recommended switch from ABS to PA6 CNF DX resulted in improved mechanical properties, a uniform surface finish, and reduced manufacturing costs—without the need for chamber heating.
Material Spotlight: PA-CNF Materials
The PA-CNF materials used are reinforced with cellulose nanofibers and, depending on the printing orientation, exhibit up to twice the strength of PA12.
Special features:
- Excellent surface finish; can be chemically smoothed if desired
- lighter than comparable FDM parts made of PLA
- can be dyed in various colors
- high mechanical and thermal resistance
Rapidobject is one of the first service providers in Europe to use these materials.
Key Technical Specifications
Component type: Small-volume production
Process: FDM
Material: PA6 CNF DX (cotton fiber-reinforced polyamide)
Geometric features:
- complex internal contours
- Cavities
- Functional elements
- Undercuts
Post-processing:
- chemical straightening
- Dyeing (yellow, orange, red)
- Incorporation of 42 insert nuts (DIN 934, steel, galvanized)
The result
The 3D-printed boxes meet all of the customer's functional and logistical requirements.
They enable secure storage, clear identification through color coding, and cost-effective production despite their complex geometry.
This use case illustrates how additive manufacturing and innovative materials can be successfully applied in industrial automotive processes.
Additive Manufacturing
Transferability
This solution is particularly suitable for:
- Transport and storage boxes for industrial use
- Small production runs with a wide variety of options
- Components with complex internal geometries
- Applications with high mechanical demands
Do you need custom enclosures or functional components for industrial applications?
We would be happy to advise you on additive manufacturing options for your application.
Contact us!
We look forward to hearing from you
+49 (0) 341 231 837 50
info@rapidobject.com