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Companies in many industries have concluded that additive manufacturing will reduce their reliance on traditional supply chains. However, a necessary prerequisite for this method is that the post-processing operation must meet the requirements of mass production.
Additive manufacturing provides companies with the potential to reduce their dependence on traditional supply chains, while making their production operations more flexible and faster. However, the post-processing of 3D printed components is often a stumbling block to achieve these goals. On the one hand, many post-processing steps still require expensive manual work. On the other hand, post-processing operations are limited to processing single components or very small production batches. This does not allow compliance with established standards for mass production, namely consistent and repeatable product quality, process control, cost-effectiveness and sustainability. AM Solutions — 3D post-processing technology is a division of the Rösler Group, which specializes in the automated post-processing of mass-produced 3D printed components, and now offers new equipment to get rid of this dilemma.
With the new S2 system AM Solutions-3D post-processing technology, the only continuous-flow shot blasting machine to date is provided for post-processing 3D printed plastic parts produced using powder bed printing systems. The plug-and-play machines complying with the Atex standard are designed for all-weather three-shift operation, and are equipped with interfaces that can be integrated into interconnected production lines. The workpiece is loaded into the machine as a complete print job. Loading is done manually or automatically. Once in the machine, the plastic parts gently pass through a special feeding belt in a one-piece flow. The tumbling action of the parts ensures that they are equally sandblasted from all sides, thus consistently and completely removing any residual powder on the surface of the part. Depending on the blasting medium used, the surface of the workpiece can also be homogenized and/or shot blasted. The machine can be equipped with up to four nozzles. The number of nozzles, spray pressure and conveying speed can be adjusted individually according to the respective workpieces. Then, these process parameters can be stored in the control panel as separate processing recipes. On average, a print job requires 15 to 20 minutes of cycle time. Depending on the condition of the original workpiece, the Ra surface roughness reading can be reduced by up to 13 µm.
In order to ensure that the shot blasting medium always maintains high quality, the compact shot blasting machine is equipped with an effective shot blasting medium cleaning and recycling system. This, combined with the integrated electronic reporting tool, ensures the repeatability of blasting results, complete process control and high cost-effectiveness of post-processing operations. A patent application covering machines and processes is pending.
The innovative C2 system allows fully automatic chemical surface smoothing of plastic parts printed in tandem with standard polymers and elastomers (including TPU). (Source: Rosler)
C2 presented as a conceptual solution illustrates that AM Solutions — 3D post-processing technology originated from the development and production of machinery and consumables for mass production. This patent-pending innovation enables automatic chemical surface smoothing of 3D printed components made up of ordinary polymers and elastomers (including TPU) in series. Therefore, for this post-processing operation, the costly single-piece processing of the workpiece is completely eliminated. The bounding box allows the processing of workpieces with dimensions from 10 x 10 x 10 to 300 x 300 x 300 mm and a wall thickness of at least 2 mm. In addition, the process also includes a newly developed non-hazardous processing medium specially developed by AM Solutions-3D post-processing technology. This ensures that the surface smoothing operation is not only environmentally friendly, but also that the subsequent waste disposal is not subject to any environmental restrictions and is cost-effective.
The patent-pending C2 chemical surface smoothing system can be modified to apply colored dyes to plastic parts. C2 will be commercially available in the first quarter of 2022.
The multifunctional wet blasting system S1 Wet can not only remove residual powder, but also surface treatment of 3D printed metal parts. (Source: Rosler)
For mass-produced metal or plastic parts, wet sandblasting is a mature and effective surface finishing process. With the S1 wet system AM Solutions-3D post-processing technology, the advantages of this surface treatment method are adapted to the specific requirements of additive manufacturing. The flexible S1 sandblasting system can be used for cleaning and surface homogenization and smoothing of various workpieces. A key feature of this technology is that the blasting medium and process water are mixed together to form a slurry. According to the initial surface roughness of the workpiece, their Ra reading will be significantly reduced. To some extent, this can even be used for internal surface channels and cavities. Since the water in the slurry forms a protective layer on the components, the process is very gentle. It also prevents media particles from penetrating into the surface of parts made of plastic and soft metals. Another advantage of the wet process is that it maintains dimensional integrity and prevents warping of precision workpieces with complex shapes and thin walls. Wet blasting can also prevent the generation of dust, so there is no need for protective Atex accessories.
Another feature of the compact plug-and-play S1 Wet system is its small footprint. In a space of only 2.6 square meters, it provides everything needed for efficient and sustainable operations. The machine integrates not only the control panel, but also the monitoring of the sandblasting system to ensure repeatable processes, air filtration devices and waste water management. The discharged wastewater flows into the sedimentation tank to collect most of the sludge. This sludge-like material can be further dewatered by the optional process water cleaning and recycling system integrated in the S1 machine. The company says this significantly reduces water consumption and waste disposal costs. Additional equipment options suitable for the corresponding processing tasks allow the use of S1 Wet, from manual processing of individual components to fully automated processing of complete batches of workpieces.
AM Solutions-manufacturing service partners specializing in services related to additive manufacturing. The scope of services covers the entire additive manufacturing process chain and is also designed to meet the requirements of mass production. To this end, the Rösler Group of Companies headquartered in Italy covers all stages of the product creation process, from the basic concept and testing of product concepts, to technical and economic feasibility studies, product development and prototype creation, to large-scale production, including Post-processing. The goal is to utilize the advantages of additive manufacturing in a component-specific way through optimized use of the most advanced technology and comprehensive expertise, thereby creating innovative components while significantly reducing development and delivery time. Market period.
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