By Cassandra Balentine
When utilizing additive manufacturing (AM) for metal part production, one challenge comes from residual or clogged powder. Depowdering systems safely extract and collect this powder in a container.
As three-dimensional (3D) printing technology advances, the complexity of printed parts is increasing. “This complexity requires sophisticated depowdering solutions that can efficiently and effectively remove powder from intricate geometries. Additionally, the need for efficient material removal and recycling is crucial for maintaining cost effectiveness and quality in AM,” states Addiblast’s website.
Automated Options
Both manual and automated depowdering processes are utilized. The best option depends on the dimensions, geometry, quantity, and material of parts.
“In recent years, automated processes have particularly been in demand. This is explained by the fact that 3D printing volumes are increasing rapidly and automation saves a lot on labor costs. Automation ensures repeatable quality and better process reliability,” offers Normfinish’s website.
The material type of the 3D printed product often affects how it should be depowdered. For example, Normfinish says the product properties of polymers require a different way of finishing than metal. “In general depowdering is unavoidable for all powder bed printed products.”
Heavy Loads
Typical large format applications include thrust chambers and heat exchangers, which are found in aerospace, transportation, and defense industries.
Automated powder extraction is the recommended solution for large amounts of powder, according to Andreas Hartmann, CEO/CTO, Solukon.
“Heavy load parts from our point of view are parts that cannot be handled manually at all since they are far too heavy. So, let’s say heavy load parts start at approximately 100 kilograms and can weight more than two metric tons,”offers Hartmann.
The demand for laser powder bed fusion (LBPF) printers for extra-large parts has risen in the last couple of years. “This can be seen, for example, in the fact that Nikon SLM has already sold its 50th NXG XII 600 system this year, according to a press release. Every large format printer sold directly creates the need for an automated depowdering solution. Not only because the components cannot be handled manually, but also in order to be able to post process the parts profitably and safely,” shares Hartmann.
It is important to always consider the total weight of the component when selecting the right depowdering system. “This means the weight of the part itself—plus the build plate—and the weight of the powder inside the component,” adds Hartmann.
Hartmann admits that significantly more components are still produced in the medium-size segment, but automated post processing is always required where large format printing is used. “We see therefore a high demand for heavy load depowdering solutions.”
Depowdering Solutions
Whether the need is large or small, depowdering solutions continue to solve challenges facing powder collection from metal AM. Here are a few options.
Addiblast
Addiblast provides depowdering solutions designed to meet the demands of AM. Its systems are engineered for efficiency, safety, and precision, ensuring optimal performance for the most complex 3D printed structures. Addiblast’s MARS series of depowdering systems are designed to provide optimal performance for different applications and needs.
Grenzebach
Grenzebach offers customized automation solutions for AM. Processes such as depowdering run quickly, reliably, and economically, increasing both efficiency and product quality of your business.
With Grenzebach’s Dual Setup Station, the downtime of industrial 3D printers caused by cooling, unpacking, and setup can be reduced. “This increases the utilization of your AM with metal powder. Productivity is boosted, and manual labor is reduced, leading to a significant reduction in unit costs per part,” according to the company’s website.
In addition, the company says employee risk is minimized, as dust loads and hazards from hot objects are reduced. This diminishes costly technical protective measures and personal protective equipment. The physical strain on machine operators is also significantly decreased by the elimination of heavy or hot component transport and open powder handling.
The Grenzebach Dual Setup Station – EOS Edition is compatible with the EOS M 400-4 system.
Normfinish
For 3D printed products printed using a powder bed printing technology, a blast principle is often used. Here there are many choices.
Normfinish offers a standard range of automated blast cabinets, the Normfinish 3D series, consisting of the 3D Solid Clean, 3D Smart Clean, 3D Excel Clean, and the 3D Samba Clean. All of these blast cabinets, depowdering units, comply with ATEX legislation, class II 3/-D T125˚. In addition, customer-specific Normfinish blast cabinets can also be developed.
Solukon
Solukon provides the SFM-AT1000-S with dimensions of 600x600x1,000 millimeters (mm) and 800 kg and the SFM-AT1500-S 600x600x1,500 mm or 820x820x1,300 mm with a maximum weight of 2,100 kg depowdering systems for heavy load systems.
For the SFM-AT1500-S Solukon offers the compatible SFM-PCU powder collection unit. The powder can be safely extracted and collected in a large container in a process monitored by sensors. Upon request, SFM-AT1500-S can be compatible with powder conveying systems of other manufacturers.
Solukon’s SFM-AT1500-S is currently the largest metal depowdering system; it features a build plate—an immense intake weight for depowdering systems. This makes SFM-AT1500-S the ideal depowdering system for heavy-duty requirements and dimensions, according to Hartmann.
Another feature that sets the SFM-AT1500-S apart, particularly where parts with enormous dimensions are produced, is its footprint. “This is why the system is as compact as possible. With special drive technology, Solukon has succeeded in making the system very narrow. The structure is also arranged so flat that no external platforms or stairs are necessary to load the parts. This makes the system unique in terms of its footprint and particularly safe and convenient when loading and handling particularly large components,” offers Hartmann.
The Solukon’s SFM-AT1500-S also features compatible software, SPR-Pathfinder. “This innovative software eliminates the need for manual programming during powder removal by using the CAD file to calculate the optimal movements for the component within the Solukon system. Users can also use the SPR-Pathfinder during the design process to check whether their complex components will be cleaned. This capability offers a unique opportunity to save substantial time and costs throughout the entire production process while significantly reducing the risk of production errors,” adds Hartmann.
Powder Collection
Manual and automatic depowdering solutions are offered for metal 3D printing. The larger the part, the more likely an automated solution is the answer.
