On the manufacturing of potted electrical connectors with 3D printing resin: an unobtrusive workflow

Abstract: The application space of additive manufacturing knows ongoing expansion due to advances in materials and improvements in equipment, but also the novel, creative use of well-established techniques. Vat photopolymerization (VPP) can be employed in the manufacturing of industrial grade electrical connectors with embedded conductive terminals. The proposed workflow includes the insertion of these terminals towards obtaining environmentally sealed connectors during the curing phase inherent to VPP 3D printing, thereby not disrupting nor adding to the original manufacturing steps. The novelty of the approach is further enhanced by potting the electrical terminals into the 3D printed substrate with the same material (thermoset resin) in which the connector body was produced. The naturally subsequent UV-curing of the full ensemble yields robust electrical connectors, mechanically tested and validated for their rigidity and ultimately characterized for their electrical performance. The complete manufacturing workflow can be extended to other commercially available connector types, relevant to a broad range of power and data transfer applications.

Keywords: Additive Manufacturing, Potting, Electrical Connectors, Polymer Welding

DOI: 10.54941/ahfe1005153

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