Eschbal revolutionizes Window Production with Sintratec S2 3D Printing

Eschbal, a Swiss manufacturer of window systems, has set new standards in production by using the Sintratec S2 3D printer. In the heart of Switzerland, in Winterthur, the company specializes in additive manufacturing of prototypes, small series and production tools.

Michael Ebnöther from the technology department emphasizes the importance of innovation, proximity to the customer and flexibility, particularly with regard to sustainability and material cycles. In addition to the production of aluminium frames and sashes, the continuous optimization and development of products is part of everyday life at Eschbal. For the flagship product, the “Sirius” window system, the team succeeded in maximizing the glass surface to let in as much light as possible.

“With the SLS process, we were especially impressed by the tolerances of up to 0.1 millimeters and the surface quality”, explains Ebnöther. “In addition, other technologies such as FDM cannot deliver the quantities we need – with the S2 we can print up to 100 parts within 24 hours”, he continues.

A decisive factor in strengthening the company’s market position is the ability to respond quickly to individual customer requirements. This is where 3D printing comes into play. “Before we invest in an expensive injection molding tool, we need something in our hands that we can test and verify,” says Ebnöther. It is crucial that the SLS parts have very similar properties to the injection molded products. Equally important is the shorter development time: “Compared to the previous process with external suppliers, the S2 saves us several days.”

The modular SLS system of the Sintratec S2 is used to produce prototype parts, production tools and small batches of window components made from robust PA12 nylon.

3D-printed parts have become indispensable for Eschbal, especially for prototypes. “Before we invest in an expensive injection molding tool, we need something in our hands that we can test and verify,” says Ebnöther. The SLS parts have very similar properties to the injection-molded products.

Eschbal also manufactures series parts for small series. For example, a reinforcing element that is only required for special profile combinations. An injection molding tool would not be profitable here, so the component is produced on the S2 if required.

Another application example is a connector that was previously heavy and bulky. To optimize it, the design was revised, quickly printed with PA12, iterated and verified. “This enabled us to reduce the weight of the new connector by 33%,” says Ebnöther. Eschbal’s production department also benefits from the SLS printer. Tools and auxiliary materials, such as the cutting bases for the cutting machine, which previously had to be commissioned, are now 3D-printed in-house for a precise fit. This is cheaper, faster and enables the company to react much more effectively to potential adjustments.

By implementing SLS 3D printing, the engineers at Eschbal have gained valuable design freedom.

“It is simply easier, faster and cheaper to push the boundaries”, says Ebnöther. For Eschbal’s development department, the Sintratec S2 has fulfilled the team’s expectations and hopes. “From the first contact until today, we are completely satisfied – the team and the support from Sintratec are a clear recommendation”, concludes Michael Ebnöther.

For Eschbal’s development department, the Sintratec S2 has fulfilled the team’s expectations. “The Sintratec S2 meets our expectations and allows us to manufacture precise prototype parts, auxiliary tools and small series in a short amount of time”, summarizes Ebnöther.