Schneider Electric Boosts Manufacturing Efficiency with INTAMSYS FUNMAT PRO 310 NEO

Schneider Electric, a renowned leader in energy management and automation, has been dedicated to optimizing resources and enhancing efficiency for over a century. At their advanced facility in Plovdiv, Bulgaria, the focus is on producing top-tier electrical components, such as the Miniature Circuit Breaker (MCB), which plays a crucial role in safeguarding electrical systems from overcurrents and short circuits.

To enhance production and minimize lead times, Schneider Electric embraced Additive Manufacturing (AM) and Fused Filament Fabrication (FFF) technologies in their 3D printing operations a few years ago. The introduction of the INTAMSYS FUNMAT PRO 310 NEO in October 2024 marked a pivotal upgrade, facilitating in-house production of essential components and streamlining overall workflow efficiency.

By leveraging 3D printing technology, the facility now manufactures all mechanical components needed for its production line internally. The FUNMAT PRO 310 NEO has been instrumental in this transformation, primarily used for printing jigs and fixtures, significantly boosting workflow efficiency. It supports a diverse range of materials, including PC, PA6, PA12, PPA, PA6-CF, and PPS, allowing the production of durable and high-quality parts.

PA6-CF + SP3030

Challenges Before Implementation

Before adopting the FUNMAT PRO 310 NEO, Schneider Electric faced inefficiencies due to traditional manufacturing methods and slower 3D printing solutions. The production of functional prototypes and custom parts was time-consuming, often causing bottlenecks in the development process. Injection molding further prolonged lead times, sometimes delaying production by up to three weeks. A faster, more reliable solution was necessary to expedite part production and improve workflow efficiency.

Why Choose the INTAMSYS FUNMAT PRO 310 NEO?

Schneider Electric opted for the INTAMSYS FUNMAT PRO 310 NEO due to its high-speed capabilities, material compatibility, and industrial-grade performance. The ability to print parts in just two hours, compared to 12 to 15 hours previously, drastically accelerates production cycles.

The printer’s automatic bed leveling and heated chamber (capable of reaching 100°C) simplify setup and ensure consistently high print quality. The high chamber temperature is particularly beneficial for engineering materials like PC, preventing warping in full-size prints and offering higher Z-strength for enhanced mechanical performance.

Moreover, its open material system allows flexibility with various materials, though Schneider Electric primarily uses INTAMSYS filaments due to their optimized profiles and superior print consistency.

Parts printed by Schneider Electric Bulgaria

IDEX Technology

The 310 NEO’s IDEX (Independent Dual Extruders) technology enables Schneider Electric to print complex parts with multiple materials in a single print job. For instance, the team designed a gripper with rubber-like properties to prevent parts from falling off production lines. By combining flexible TPU95A and structural PETG, they created a durable, high-quality component that facilitates smooth production.

Additionally, Schneider Electric utilizes IDEX technology to produce welding jigs with complex geometries for use inside their factory machines. By combining PA6-CF with soluble support material SP3030, they can create these parts in under six hours—significantly faster than traditional methods.

Printed parts with the 310 NEO

Implementation and Results

Since integrating the FUNMAT PRO 310 NEO, Schneider Electric has observed a remarkable improvement in production efficiency. Key benefits include:

  • Drastic Reduction in Print Times: Parts that previously took 12 to 15 hours to print can now be completed in just two hours, dramatically accelerating production cycles.
  • Shortened Development Cycles: Faster printing enables the team to iterate and test jigs and fixtures more efficiently, significantly reducing development time and speeding up prototyping and validation.
  • Expanded Design Possibilities: IDEX technology allows for the production of complex geometries with multiple materials, reducing reliance on traditional manufacturing methods and enabling more advanced designs and quicker prototyping.
  • Consistent and High-Quality Printing: Features like automatic bed leveling and a heated chamber ensure consistent quality and minimize errors during printing, resulting in high-quality parts with every job.
  • Cost and Resource Optimization: By increasing in-house production, Schneider Electric has reduced outsourcing costs, improved material utilization, and enhanced operational efficiency.

The adoption of the INTAMSYS FUNMAT PRO 310 NEO at Schneider Electric’s smart factory in Plovdiv, Bulgaria, has significantly enhanced efficiency, flexibility, and cost savings. The integration of 3D printing technology continues to drive innovation in the production of electrical components.

With their Smart Factory certification, Schneider Electric plans to expand its 3D printing operations to further increase in-house production of components and spare parts, reducing maintenance costs and improving self-sufficiency.

This success underscores the transformative potential of 3D printing in modern industrial environments, demonstrating how the INTAMSYS FUNMAT PRO 310 NEO can redefine manufacturing processes for greater efficiency and innovation.