3D Printing for Electrical Connectors

The Figure 4 135 is a compact, high-speed DLP production system engineered for flame-retardant, end-use thermoplastic replacement parts. Its certified FR materials make it uniquely suited for regulated industrial environments where ignition risk, dielectric breakdown, or flame toxicity cannot be tolerated.

Combined with 3D Sprint® software automation, the Figure 4 135 enables manufacturers to bypass tooling, shorten development cycles, and deliver low- to mid-volume production parts at a fraction of the cost of injection molding, while maintaining tight tolerances and repeatable performance.

Figure 4 135 Applications & Materials Used

Automotive Application: Wire Harness Clip

Material: Figure 4® TGH FR V0 BLK
Industry Requirements: Electrical safety, fluid resistance, flame compliance, vibration durability

The wire harness clip secures and organises electrical cabling inside vehicles, often near heat sources, fluid reservoirs, and power distribution systems. Traditional injection-molded clips require long lead times and expensive tooling when design changes occur. With the Figure 4-135, these parts can be rapidly produced, tested, and deployed without tooling delays.

Material Performance

• UL94 V0 rating at >3 mm wall thickness prevents flame propagation

• Meets FAR 25.853(a) at 3 mm and above 2 mm, supporting aerospace crossover use

• Self-extinguishing and flame-retardant, ideal for engine bays and battery systems

• Resistant to oils, fuels, coolants, and automotive fluids

Production Impact with Figure 4 135

The system can support engineering validation, pre-production, and low-volume manufacturing using the exact same geometry and material — eliminating redesign for molding.

• Batch Time: 3:24

• Unit Time: 0:51

• Parts/Build: 4

This enables on-demand manufacturing, supports late design changes, and reduces inventory waste.

Electronics Application: Momentary Switch Connector

Material: Figure 4® TGH 75C FR BLK
Industry Requirements: Dielectric reliability, thin-wall flame resistance, repetitive snap loads

Momentary switches require tight press-fit tolerances, stable electrical insulation, and mechanical endurance under constant actuation. The Figure 4-135 prints these parts with micron-level precision, enabling crisp snap fits without swelling or warping.

Material Performance

• UL94 V0 flame rating at just 0.4 mm, exceptional for thin parts

• 75°C HDT for thermally loaded enclosures

• Glow Wire Ignition (GWI) 800°C, a key safety test for electrical fires

• Comparative Tracking Index (CTI) 600V, minimizing risk of conductive carbonization

• RTI: 150°C electrical / 130°C mechanical, ensuring long-term insulation reliabilityProduction Impact with Figure 4-135

Production volumes can be scaled flexibly without cutting molds.

• Batch Time: 1:22

• Unit Time: 0:05

• Parts/Build: 15

The process supports rapid iteration and certification testing, dramatically reducing time to market for consumer devices and industrial electronics.

Aerospace Application: Drone Motor Mount

Material: Figure 4® TGH FR V0 BLK
Industry Requirements: Weight optimization, thermal safety, chemical resistance, secure hardware interfaces

The drone motor mount houses propulsion components that generate heat and friction, and may be exposed to aerosols, oils, and high-velocity particulates. This part requires high stiffness, flame resistance, vibration tolerance, and chemical compatibility.

Material Performance

• UL94 V0 at >3 mm ensures a safe response to electrical or thermal failure

• Meets FAR 25.853(a) flame resistance standards for flight-rated interiors

• High stability when exposed to oils, propellants, & cleaning chemicals

• Self-extinguishing polymer structure reduces risk in failure scenarios

Production Impact with Figure 4 135

Complex aerodynamic shapes are printed without tooling, enabling design iteration for heat dissipation, air channels, and cable routing.

• Batch Time: 0:49

• Unit Time: 0:24

• Parts/Build: 2

This accelerates drone development from prototype to limited-run production.

Electronics Application: Backplane Connector

Material: Figure 4® TGH 75C FR BLK
Industry Requirements: High-density pin layout, insulation stability, flame safety, dimensional precision

Backplane connectors require tight tolerances in multi-pin housings, where even small deformations can cause high-resistance faults, thermal hotspots, or signal failures. The Figure 4-135 prints these delicate geometries consistently and repeatably, making it an ideal solution for industrial control systems and power electronics.

Material Performance

• UL94 V0 @ 0.4 mm, enabling thin-wall connector housings

• CTI 600V protects against conductive carbonization in high-voltage systems

• GWI 800°C provides ignition resistance under short-circuit conditions

• RTI up to 150°C, protecting insulation under sustained load

Production Impact with Figure 4-135

Additive manufacturing eliminates connector mold costs, especially for frequent design variants.

• Batch Time: 2:02

• Unit Time: 0:11

• Parts/Build: 11

This enables distributed, on-demand production without supply chain delays.

Why Manufacturers Choose the Figure 4 135…

The Figure 4-135 provides:-

✔ Certified flame-retardant materials meeting UL94, FAR 25.853, CTI, & GWI standards
✔ Tight-tolerance DLP accuracy ideal for small functional components
✔ Reduced cost vs injection molding, especially at low-to-mid volumes
✔ Fast cycle times for agile engineering and production
✔ Automated build preparation & repeatability via 3D Sprint

This makes it a reliable solution for end-use regulated parts in:

• Aerospace drones & avionics

• Consumer & industrial electronics

• Automotive EV systems & under-hood assemblies

• Electrical housings, switches, and connectors