Stratasys, a printer manufacturer in the field of additive manufacturing, relies on the S1 from AM Solutions – 3D post-processing technology, a brand of the Rösler Group, at its Additive Manufacturing Center in Rheinmünster. With this system, the company significantly improves the surface quality of parts produced using the SAF process and achieves uniform, reproducible results. Additionally, the S1 enables a combined 2-in-1 process for the first time: cleaning and surface finishing occur in one step, in just one system, with only one medium. This increases efficiency, reduces space requirements, and lowers operating costs.
Post-processing also plays a crucial role at the Additive Manufacturing Center in Rheinmünster. There, components for various industries such as automotive, medical, aerospace, and defense are manufactured for the entire EMEA region – from prototypes to tool components to end parts, whether as customer samples, trade show parts, or as backup prints in case of technical issues. For Stratasys, post-processing is a central step in successfully establishing additive manufacturing as an industrial production technology. “While the printing process is already highly automated, many post-processing steps are still time-consuming and partially manual. Automated solutions enable the standardization of these processes, shorten lead times, and ensure high, reproducible quality,” says Dennis Kronimus, Additive Manufacturing Center Manager, Stratasys EMEA.
Significantly better surfaces with 25% time savings thanks to integrated 2-in-1 process
Especially for parts produced using the SAF process, post-processing is of great importance. SAF (Selective Absorption Fusion) refers to the powder-based additive manufacturing technology from Stratasys, developed for the industrial production of polymer parts. Since it produces large batches of parts with excellent mechanical properties, efficient and repeatable post-processing is essential to achieve consistent surface quality. Until now, Stratasys used an automated solution from a competitor for cleaning its parts made using the SAF process, which worked with glass beads – an additional surface finish was not performed. The process was functionally reliable for a long time, but with increasing quality demands, it reached its limits. The decisive factor for choosing the S1 from AM Solutions was the significantly better surface quality and the associated advantages for downstream processes, such as coloring. At the same time, the machine impresses with its thoughtful design, which greatly simplifies maintenance and operation in everyday use.
In addition to the improved component quality, the S1 also scores in terms of cost-effectiveness. “Thanks to the S1, the process steps of depowdering and surface finishing can be carried out in a single pass with only one medium, for which we would otherwise have needed two systems. This has significantly increased the efficiency of our SAF post-processing and achieved a 25% time savings while simultaneously providing a better surface finish. Additionally, we require significantly less floor space – a crucial advantage in our technology center with its multitude of machines,” says Dennis Kronimus.
While previously the cleaning of parts was done with glass beads, it is now done with polybeads. They are more durable and also lead to a significantly better surface result. The durability of the blasting medium used is also ensured by the sophisticated blasting medium preparation system of the S1. Here, filters, cyclones, and blasting medium sieves are optimally coordinated and reliably separate the blasting medium from the powder.
C1 and jointly developed PowderEase T1 in use
In addition to the S1, Stratasys at the Rheinmünster site also uses the PowderEase™ T1 developed in collaboration with AM Solutions. It was specifically designed for the H350 SAF printer and is manufactured at the AM Solutions site in Untermerzbach. The system combines automated unpacking, powder recovery, and dosing for up to six printers. This significantly reduces manual effort while increasing workplace safety and powder recovery – a clear economic and ecological advantage.
Additionally, Stratasys uses the C1 for automated support removal from 3D-printed parts produced using the PolyJet or industrial FDM processes. From the company's perspective, the solution contributes to increased workplace safety. Furthermore, a change of the process medium is required much less frequently than with other solutions, as it is continuously sieved. Coarse support structures can thus be removed from the bath without being dissolved.
Collaborative partnership
The decisive factors for Stratasys in choosing AM Solutions were not only the convincing product portfolio but also the decades of experience of AM Solutions and the Rösler Group in surface treatment. The ability to post-process their own components directly on-site and immediately assess the results was particularly valued. The uncomplicated collaboration and quick responsiveness were also convincing. That the collaborative partnership is now being further deepened with the integration of the S1 is commented on by David Soldan, Head of AM Solutions – 3D post-processing technology: “We are very pleased that our successful collaboration with Stratasys, which began with the development and implementation of the PowderEase™ T1 and the acquisition of the C1, is now being further deepened with the integration of the S1. For us, this is a strong sign of mutual trust and proof that two companies with the highest quality standards can achieve real progress in industrial additive manufacturing together.”
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