Low-noise motion simulator thanks to 3D printing filaments and linear plain bearings

Pleasant driving experience with igus® sliding components

DIY car racing simulators are becoming increasingly popular as a hobby. After a long day at work, school or any other activity, amateur racers sit down in their simulator and enjoy the realistic motion simulation of a car interacting with the terrain and environment. Today's technology allows the driver to move in different directions. However, this is accompanied by noise caused by the interaction of the system's many mechanical components.

Fortunately, the wear-resistant plastic bearings from igus® can significantly reduce the noise while ensuring stable and precise movement of the various parts. The following application case by Mr Volker Krebs from VKC Services Ltd. shows how noise can be reduced in a motion simulator. This is achieved by replacing all metallic ball bearings and ball screw nuts with tribologically optimised components from igus®.

What was needed: Low noise bearings and lead screw nut to stabilise the linear movement within the simulator
Manufacturing process: Filament extrusion (FDM)
Requirements: Wear resistance, durability, high flexural strength
Material: iglidur® i150 & iglidur® i190 tribofilaments
Industry: DIY solutions
Success for the customer: Improved driving experience due to noise reduction, less maintenance due to freedom from lubrication

Problem

Like many fans of simulated car racing, Mr Krebs usually only has time for his hobby after work. However, the noise emitted by the simulator can be disturbing for other household members or even neighbours. On the one hand, the noise is caused by the humming of the engine, which is why he has installed a new soundproofed engine. Unwanted noise is also caused by the metal ball bearings during linear movement on the shafts and actuators of the simulator. The same applies to ball screw nuts, which are guided along rotating threaded spindles. The declared aim was therefore to reduce the friction between the components and thus minimise noise pollution.

Solution

The self-lubricating specifications of the igus®-plastic enable smooth and low-noise sliding. The standard linear plain bushes drylin® R RJUM-01 and RJM-01 were used as a replacement for ball bearings. The bushings of the RJUM-01 model fitted perfectly when they were mounted in the bearing blocks 3D-printed by Mr Krebs. Where the standard sizes of the drylin® linear bushes did not fit, bushes were 3D printed from iglidur® i150 filament and also mounted in bearing blocks. The 3D printing also made it possible to manufacture lead screw nuts from iglidur® i190, which are similar in design to the original metal ball nuts.

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iglidur® i190 filament in the friction test

The friction between a lead screw nut and a threaded spindle can be creatively tested by first supporting the lead screw nut vertically on metal rods. The spindle is then positioned in the lead screw nut so that its weight presses on it. It is then checked whether the lead screw driven by a stepper motor can rotate despite its vertical suspension. This would be a clear indication that it is not blocked by its weight and can therefore rotate with low friction under normal conditions in the simulator. As can be seen in the video, the suspended spindle can rotate without restriction within the lead screw groove printed from iglidur® i190.

More about the special features of the iglidur® i190 filament

The upgrade to 3D-printed sliding components

Like many owners of DIY driving simulators, Mr Krebs enjoys online car racing. In a real car race, you might hear the engine of the car humming, but can you also hear the grinding of gears or the movement of shafts? Probably not. To create a more realistic driving experience, the mechanical noises in a driving simulator should therefore be reduced to a minimum. Replacing metal plain bearings and lead screw nuts with those made from the tribologically optimised polymer from igus® is made easier by 3D printing.

The main advantage of additive manufacturing is design freedom. Based on existing bearings, lead screw nuts and the corresponding bearing blocks, components with the same dimensions can be 3D printed. It is also often the case that several attachment points in the simulator's rig require bearings in non-standardised sizes. In such cases, you can first design a CAD model of the sliding component and have it printed by the 3D printing service from igus®. The resulting part withstands loads of up to 54 MPa trade show when printed from the iglidur ® i150 filament, and up to 80 MPa when made from iglidur ® i190. In addition, the printed parts rarely require maintenance as they are self-lubricating and wear-resistant.

3D printing also offers the possibility of testing. If you have a printer, you can replace some of your bearings or lead screw nuts with iglidur® prints. If you notice that the noise development decreases, it is worth printing the other sliding elements from iglidur® as well.

Also discover our free guide with tips for filament 3D printing.

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