Replacement gears withstand high loads in use

Application Overview

• What was needed: Special load-bearing gears for the repair of servomotors in the roof turrets of large airport fire engines
• Manufacturing process: Laser sintering
• Requirements: Cost-effective, highly resilient
• Material: iglide® i3
• Industry: Commercial vehicles
• Success for the customer: The gears withstand the high load trade show and were used for the repair of other vehicles. The company was thus able to avoid the cost-intensive replacement of the entire servomotors.

Fraport AG's plant fire brigade ensures fire protection at Frankfurt Airport, using large fire engines equipped with roof turrets. A servomotor adjusts the spray nozzle angle, even while discharging water, subjecting it to high stress. After ten years, the gears wear out, requiring turret repairs to maintain functionality.

Roof turrets of large airport fire engines have to withstand intense loads while discharging water

Frankfurt Airport, Germany’s largest commercial airport, is a major hub for passenger and cargo traffic in Europe. With nearly 81,000 employees across 450 companies, it plays a vital role in the Rhine-Main region’s economy. Given the high density of aircraft and vehicles, the airport fire service stays constantly active. To meet legal response times, its three fire stations must reach any location on the apron within three minutes.

The fleet includes 115 fire engines, including 14 large airport fire trucks. Their roof turrets can discharge over 5,300 liters of water more than 80 meters in a minute. The actuators controlling the water jet’s angle endure extreme stress during operation.

Printed gears made of iglide® i3: Successfully in use in large airport fire engines

Two durable plastic gears inside the servomotor wore out after ten years, requiring maintenance on the roof turrets. The manufacturer recommended replacing the entire servomotor, but the high cost led engineers to seek an alternative. After researching, they discovered igus® 3D-printed gears and tested the wear-resistant iglide® i3 material.

Using igus’ free online CAD configurator, they quickly designed a replacement. The SLS printing process took under three days, allowing for rapid testing. The new gears withstood the high load, leading to reorders for more vehicles. Impressed by the quality and fast service, the team also 3D-printed a component for the fire trucks' pneumatic doors, which is now successfully in use.

Why print gears from iglide® i3?

iglide® plastic, engineered for moving machine parts, offers exceptional abrasion resistance and built-in solid lubricants. Used in injection molding, additive manufacturing, and machining, it ensures durability across applications. iglide® i3, a high-strength powder for laser sintering, is igus’ top-selling 3D printing material due to its superior wear resistance.

Ideal for spur and bevel gears, iglide® i3 provides long-lasting performance, while iglide® i6 is best suited for 3D-printed worm gears requiring enhanced sliding properties. The online gear service life calculator helps determine durability under specific conditions.

A major advantage of 3D-printed gears is the ability to optimize the tooth root geometry, extending service life—something typically limited in traditional machining. For precise customization, igus® offers a free CAD configurator to streamline gear design.