Innovative 3D Printing Solution for Custom Gas Diaphragm Pump Head
- August 21, 2025
- News
- 2-3 minutes
Thomas is a leading manufacturer of systems, compressors, vacuum, and liquid pumps for Original Equipment Manufactures (OEMs) in the medical, laboratory, environmental and industrial sectors. Visit https://www.thomaspumps.com/en/ for more information.
Brief introduction to the problem
Problem Statement: Thomas’s client required a bespoke head for a gas diaphragm pump, tailored to fit within a novel device they were engineering. The complexity of the design aimed to minimize the product’s footprint, which rendered traditional injection molding a challenging option. The client also sought a rapid market entry, targeting less than a year, with initial production volumes estimated at several hundred units, increasing to approximately 2,000 units annually.
Problem Statement: Thomas’s client required a bespoke head for a gas diaphragm pump, tailored to fit within a novel device they were engineering. The complexity of the design aimed to minimize the product’s footprint, which rendered traditional injection molding a challenging option. The client also sought a rapid market entry, targeting less than a year, with initial production volumes estimated at several hundred units, increasing to approximately 2,000 units annually.
The routes to a solution
Standard Solution: Thomas’s engineering team typically adopts a two-phased approach for custom projects, starting with prototyping and followed by a production ramp-up. Initially, they utilize an in-house SLS (Selective Laser Sintering) system for low-volume prototyping. The subsequent phase involves transitioning to injection molding, which, despite a high initial tooling cost and a lengthy preparation period (6 months to a year), is cost-effective for large-scale production. However, given the time-sensitive and cost-constrained nature of this project, the standard injection molding route was deemed unsuitable.
Soft Tooling Manufacturing Solution: An alternative was the creation of a low-cost soft tool, which offered reduced initial investment and shorter lead times. However, the per-unit cost remained prohibitively high, failing to offer a significant advantage over the standard process.
Additive Manufacturing Solution: Considering the part’s complexity, tight timeline, and cost constraints, the team identified 3D printing as a viable production method. This approach promised the quickest time-to-market and appeared to be the most cost-effective among the options considered.
For the selection of the most suitable additive manufacturing technology, the team prioritized technical capability while also being mindful of costs. Key technical requirements included:
- Temperature Stability: Capability to withstand temperatures above 80°C due to pump head heat.
- Durability: Strength to prevent cracking when fitting rubber tubing onto barbs.
- Rigidity: Ensuring part flatness to prevent leakage when clamped to the pump assembly.
- Surface Finish: Must support sealing with a gasket and provide a dynamic seal for the check valve.
- Resolution and Tolerance: Ability to achieve fine details with specific height and tolerance requirements.