ATEX certification for machines in explosion risk areas with 3D printing of ESD special parts
igu-blog-adm | 26. October 2020
Even a small spark in a potentially explosive atmosphere, can have devastating consequences for personnel and the entire plant. However, friction – especially friction of moving plastic components against each other – causes sparks. In order to permanently protect these components from irreversible damage, a controlled discharge is necessary. This means that materials with defined surface resistances must be used that are neither insulating nor conductive, i.e. statically or antistatically conductive. For this reason, metal components are often used for machines and equipment in explosion risk areas which requires maintenance and increases weight and noise.
iglidur I8-ESD: 3D printing polymer with electrostatic dissipative properties
Conductive standard parts that prevent spark formation have long been part of the igus catalogue product range. New on the market and already in great demand is the new laser sintering material iglidur I8-ESD. With a contact resistance of 10^6 to 10^9 Ohm * cm this laser-sintered polymer is dissipative. Using the laser sintering powder, individual components can be produced with the igus 3D printing service in a maximum of 3 days (also overnight in special cases) in quantities from 1 to 10,000. Like all tribo-polymers from igus, iglidur I8-ESD is characterised not only by its dissipative capacity, but also by a particularly high abrasion resistance and particularly long service life. The wear resistance was tested in comparison to common 3D printing plastics and proved to be 2 times higher than with PA12 in the pivoting test. The solid lubricants contained therein contribute to a considerable reduction in maintenance costs.
Do iglidur I8-ESD components comply with the ATEX product directive?
The material iglidur I8-ESD and the components made of it are conductive and prevent electrostatic discharges. This makes them suitable for the construction of machines and equipment requiring ATEX certification – but the official approval for use in potentially explosive atmospheres must be granted on a case-by-case basis and for the entire machine.
Which machines require ATEX certification?
All machines, plant or equipment, whether electrical or not, which could be a source of ignition must be certified as ATEX products. Possible ignition sources in potentially explosive atmospheres are hot surfaces, flames, hot gases, heat or sparks generated by friction, static electricity, electromagnetic fields and high-frequency waves, optical radiation, ionising radiation, ultrasound, shock waves, chemical (exothermic) reactions and lightning.
Pumps, fans, safety vacuum cleaners, torches and of course an unmanageable number of special machines with valves, couplings, bearings, gears and other moving components, which can produce heat or sparks when in use, are among the most frequently used devices in explosion risk areas during production and must be designed accordingly.
Fast and economical way to ATEX-certified equipment
Especially for the manufacture of special machines, iglidur I8-ESD offers considerable savings potentials through additive manufacturing. Individual or volume customised components, spare parts or prototypes can be digitally designed within a few days and ordered via a STEP model using the online 3D printing service. Production upon delivery takes place within a few days, which saves valuable time. Since the costly production of tools is no longer necessary, just like the much more complex and expensive mechanical production for special parts, development and production costs are also reduced as are the acquisition costs for equipment and machines that comply with ATEX directives.