Worldwide, more than 40 3D printers are in use at REHAU, primarily in the development departments. "We can produce parts quickly according to our own needs," says Dr Bernhard Häupler, who heads the 3D printing team. Mainly prototypes and tools for manufacturing are produced this way - i.e. those of which only a small number of pieces is needed. 3D printing often helps, when designs are very demanding or complex. Due to the high speed that can be achieved in 3D printing, developments progress quickly. Functions can be tested on real components - and customers can be convinced. REHAU manufactures a wide range of products, which makes it exciting but demanding: "The demand is broad, the requirements are very diverse," says Dr Bernhard Häupler.

When conventional toolmaking reaches its limits, 3D printing can help. It enables clever design solutions that can be produced quickly and thus tested. Moreover, there are cases where a single part replaces many components. "For example, we have already been able to print a calibration that consisted of 50 individual components as one part. That is already impressive. In addition, in this case we have also achieved a process improvement through integrated cooling," says Helmut Bleier.

The 3D printing team is a young one at REHAU. In 2018, the department was founded. "We are responsible for complex topics, or when colleagues from the specialist departments need help with a tricky question," says Dr Bernhard Häupler. Simpler implementations, of course, already take place directly in the development departments and plants. "Our job is a lot of fun because we make a tangible difference. But it is not always easy," says Dr Bernhard Häupler. "That's exactly where the motivation lies. That you solve problems as a team." By the way, 3D printing is not only fun for manufacturers. The technology enables increasingly individual and personalised products. Moreover, that, of course, benefits the customer. "The economic viability of 3D printing for these cases is still limited, but we expect a technological leap in the next few years that will change that," says Dr Philipp Matthes, an expert in plastic 3D printing.