广泰永立散热风扇研发案例：3D打印将研发周期从10天缩短至1天

广泰永立成立于1996年，主要生产散热风扇、水泵、EC风扇、大风扇和微风扇等产品，客户群体涵盖新能源汽车、光储光伏、储能、充电桩、服务器电源等工业控制领域。

随着AI算力、新能源汽车和储能系统的快速发展，散热系统正成为工业设备稳定运行的关键。

在引入3D打印技术之前，广泰永立将设计想法转化为实物需要约10天时间。

散热风扇属于精密产品，客户关注的性能指标包括风量、风压、噪声、功耗和效率。扇叶设计包含安装角、内倾角、外倾角等十几组角度参数，精度要求很高。

任何一个角度与设计值出现偏差，都可能导致产品性能无法达到预期。

广泰永立采用16949标准开发体系，从项目立项到量产需要经过多个阶段。接到客户需求后，会根据需求设计整体框架结构，通过仿真提前验证性能是否达到要求。如果没有达标，就需要反复迭代修改。

新品从立项到量产，需要经过C1阶段（设计审查）到C2A阶段（手板制作）。对于声音、效率有较高要求的产品，在C1和C2A之间可能需要迭代5到10次。

传统手板加工主要依靠CNC方式，加工周期基本是7到10天。对于一些复杂结构设计，传统CNC的刀具难以触及内部，无法完成这些特征的加工。工业风扇产品性能的实现，需要流体力学、结构设计、材料选择、电机控制和噪声控制的综合设计。

引进3D打印机后，广泰永立的研发流程得到了简化。

早上完成3D设计图，下午就可以用3D打印机打印出来，当天完成组装测试并验证是否达到目标参数。

传统工艺需要10天完成的工作，现在可能只需要1天。

对于广泰永立来说，3D打印的价值不是"做模型"，而是让设计更快进入真实测试。

目前3D打印主要应用于研发阶段，即手板和设计反复迭代阶段。手板打印后会进行风量风压测试、在风动设备上做性能测试、在无响室进行声音和声品质测试，以及送到客户端进行整机产品节热测试。

只有经过真实测试验证的样件，才能真正提升研发效率。

广泰永立目前主要使用PEEK材料。

选择PEEK的原因包括高耐温性、强度、尺寸稳定性和表面光洁度。

该风扇产品的最高转速已达到5万转。在高速旋转时，风阻很大，如果材料强度不足，可能导致扇叶变形，进而影响整体产品性能。客户将手板品装入整机设备进行实测时，设备环温可能达到100度左右，对材料耐温性有较高要求。

在表面光洁度方面，广泰永立曾尝试过PA、PETG等材料，但打印出来后表面粗糙，需要打磨和喷漆处理，流程复杂且影响研发效率。

PEEK打印出来的扇叶面光滑，可直接使用。

After thorough research and benchmarking, WEERG chose INTAMSYS as their supplier. The INTAMSYS FUNMAT PRO 410 met all their requirements with features like a heated chamber, dual heated nozzles, and a heated filament chamber.

INTAMSYS offered one single solution that got it all:

A robust printer with a sleek aesthetic finish, heated chamber, dual heated nozzles, and heated filament chamber.
Free and user-friendly software with incorporated printing settings (Click and Print experience) for a wide range of materials (from PA12-CF to PEEK).
Reliable support, and most importantly for WEERG, honesty and a true partnership.

WEERG also appreciated the user-friendly software with incorporated printing settings and the reliable support from INTAMSYS.

We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector.

Alex Di Maglie
Managing Director, 4D Concepts

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FUNMAT PRO 410
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Print Larger, Print More
OPEN

Open-Sourced Filaments

3D PRINTER

FUNMAT HT
COST EFFICIENCY

Lower Cost, Shorter Lead Times
MATERIAL SUPERIORITY

Versatile INTAM™ Polymers

Tank Holder

The tank holder is a new part in this year´s racing car. The part is printed on the FUNMAT PRO 610HT with the material choice of ABS. For the driverless disciplines, the team uses pressurized air to activate the brakes in an emergency. This year, they changed the concept of how pressurized air is stored, which required a new mounting solution. The tank holder is designed to solve this challenge.

Flap Ribs

Other 3D printed parts, using the FUNMAT PRO 610HT and PC material, are the flap ribs that play a crucial role in the construction of the car’s side wing. These ribs are glued into the carbon-fiber shells and incorporate threaded inserts for attaching the wing to the chassis.

While the team has used these ribs for years, they have redesigned for this season to accommodate changes in the aerodynamic shape of the wings. Using INTAMSUITE™ NEO and the 3D printing technology, they conducted topology optimization to achieve the lightest possible geometry, resulting in an organic shape that would not be possible to manufacture by milling.

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广泰永立：从10天到1天，3D打印让散热风扇研发提速

挑战

3D打印带来的改变

PEEK材料的选择

为何选择远铸智能

4D Concepts – prototype of a temperature-resistant pulley made of glass-fiber reinforced PEEK (PEEK-GF).

The application of high-end filaments made of high-performance plastics such as PEI is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of PEI 9085.

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