by Industrial Print Magazine Staff
Systems that offer automated post processing of a three-dimensional (3D) printed part are integral to the technology moving and excelling past prototyping and into full serial production. As more manufacturers consider and ultimately adopt additive manufacturing (AM), a post-processing solution is increasingly part of the equation.
German Automobiles
Solukon Maschinenbau GmbH is a well-known supplier of post-processing systems, specifically powder removal and processing solutions for metal and polymer AM. In November 2023, the company announced that automobile manufacturer, The BMW Group, integrated a post-processing system from its portfolio into its Additive Manufacturing Campus located in Oberschleissheim, Germany.
Just outside of Munich, the facility opened in 2020. It houses nearly 50 industrial systems for processing metal and plastics. The community combines production of prototype and series parts, conducts research into 3D printing technologies, and offers associate training on tool-less manufacturing.
BMW plans to use the Solukon SFP770 to unpack and clean prototype parts made of polyamide. It consists of a combined automated unpacking and blasting unit for surface cleaning and finishing with ionized compressed air for selective laser sintering parts.
Four-Step Process
Using the SFP770, the cleaning process occurs in four main steps. The first, loading, where the build box of the 3D printer is placed in the system by a lift truck. Second, unpacking. Here, a vibrating sieve cover is placed over the inserted build box, which then rotates gently overhead following an optional programmable process, gradually unpacking the components. The loose powder is extracted from the sieve cover directly and without contamination, and then conveyed to a recycling unit.
During the third step, transferring, the build box rotates towards a basket and opens the sieve cover. The sieve cover now functions as a slide and the parts are slipped carefully into the basket. If necessary, the automatic transfer process can be paused to manually remove certain components that should not be cleaned automatically.
The fourth part of the process is when the cleaning occurs. The basket rotates in the direction of the blasting unit and begins turning. The fully automated cleaning process consists of glass bead blasts and ionized air, which removes residual powder. Users easily program online process parameters such as rotation angle, blast intensity, distance, and basket rotation.
Advantages of the SFP770
BMW uses the SFP770 to clean plastic parts, specifically polyamide. There are a few reasons the technology was integrated and validated into its production line.
“Because so many process parameters can be programmed, the SFP770 achieves the best cleaning results, regardless of the part material and without any manual intermediate steps. Another advantage of our system—parts of different shapes and sizes can be cleaned at the same time,” explains Andreas Hartmann, CEO/CTO, Solukon.
Both of these benefits significantly increase the level of flexibility in prototype post processing. “Especially for companies with a high part output. The SFP770 is an ideal cleaning and unpacking station. It unpacks and cleans a fully loaded build box with an assembly space of 150 liters in only 30 minutes, which is why it can handle several jobs per day,” adds Hartmann.
Post-Processing Needs
To meet high levels of production, BMW chose to implement the Solukon SFP770. AM is more than just the printer, it requires an efficient post-processing solution as well.
Feb2024, Industrial Print Magazine