Additive manufacturing using Selective Laser Sintering (SLS) enables the economical production of complex geometries, functional prototypes, and small series. However, only reproducible and economical post-processing makes the components truly marketable. Surface quality, process stability, and costs per component are significantly influenced by post-processing. This challenge was also faced by the German 3D printing service provider FORMRISE. The company, with over 20 years of experience in additive manufacturing, supplies customers from demanding industries such as automotive, aerospace, medical technology, as well as the luxury goods and jewelry industry. Accordingly, the requirements for quality, reproducibility, and process reliability are high.
Limits of a multi-stage post-processing concept
The post-processing of SLS components at FORMRISE initially took place through several consecutive blasting processes on equipment from a market competitor. First, the components were cleaned with glass beads to remove excess powder. Subsequently, a pre-compression of the surface was carried out with polybeads before the parts were dyed and finally blasted again.
This multi-stage process was spread over several systems and sometimes required manual processing – in individual cases up to two hours per batch. However, with increasing utilization and higher quality requirements, this concept became increasingly inefficient. Particularly problematic was the preparation of the blasting media. The previous preparation solely through cyclone separation was insufficient to reliably separate blasting media and powder and ensure consistently clean preparation. The result was an extremely high consumption of polybeads.
At the same time, the quality of the blasting media continuously deteriorated because color particles and abrasion were not cleanly separated. This had direct effects on process stability: light components could not be processed arbitrarily in contaminated systems. FORMRISE was forced to plan production strictly: light parts at the beginning of the week, darker parts later on. Spontaneous customer orders or last-minute changes were hardly feasible. At the end of the week, the systems also had to be thoroughly cleaned.
Another problem, known to many SLS users, arose: when cleaning with glass beads, fine glass particles repeatedly remained on the surface. At the latest when dyeing the components, these inclusions led to inhomogeneous color results and visible defects.
S1 from AM Solutions convinces FORMRISE with superior technology
In this context, FORMRISE specifically searched for a new solution for the post-processing of its SLS components. A system was required that efficiently combines cleaning and surface finishing and, above all, has a powerful, reliable blasting media preparation.
At Formnext 2023, FORMRISE first encountered the S1 from AM Solutions. The system combines the decades of blasting technology expertise of the Rösler Group with a process concept specifically developed for additive manufacturing. The blasting media preparation system, tailored to plastic powder bed applications, with a large cyclone and integrated vibrating screen, forms the central element and ensures clean classification of the blasting media. However, what was crucial for FORMRISE was not only the technology in detail but the holistic approach: with the S1, cleaning and homogenization of the surface can be carried out in a single automated 2-in-1 process – with just one blasting medium and in one system. Due to the high satisfaction with the S1, FORMRISE now operates three systems of this type.
Significantly measurable improvements in ongoing operations
After the commissioning of the new systems, measurable improvements in post-processing quickly became apparent. The consumption of polybeads decreased by more than 60% within the first year, as the blasting media is held in the cycle much more efficiently. This alone saved around 1.6 tons of CO₂. At the same time, the use of glass beads could be almost completely eliminated, which also meant that the known problems when dyeing the components practically no longer occurred. In addition, disposal costs were significantly reduced.
Another important effect was the increased process performance of the system. Due to the high blasting power and the elimination of several process steps, the total post-processing time could be reduced by almost 50%. This not only lowered the energy and compressed air demand but also significantly reduced manual labor. The quality of the components could also be further improved. The surfaces of the SLS components are more homogeneous and appear significantly higher quality. Customers report that the components look almost polished after the blasting process, even though they were only blasted and are better suited for downstream processes.
The S1 as a strategic building block in SLS post-processing
Overall, the annual savings at FORMRISE amount to around €35,000, with more than half of that coming solely from reduced compressed air consumption. At the same time, CO₂ emissions from the post-processing process could be reduced by more than 12 tons per year. "For the post-processing of SLS parts, AM Solutions offers a solution with the S1 that is absolutely unmatched in the market and has convinced us in every respect. You can clearly see the potential in optimally aligning the blasting process to the requirements of additive manufacturing and specifically to the preparation of blasting media. AM Solutions has recognized and fully exploited this potential, giving us the opportunity to optimize our post-processing in a way we could not have imagined before," says FORMRISE managing director Peter Spitzwieser.
SLS service providers are under massive cost pressure due to competitors, market demands, and rising customer expectations. The S1 elevates efficiency in post-processing to a whole new level: higher throughput, clean results, and significantly less manual effort – without compromising on quality.
Case study for download: www.solutions-for-am.com/CaseStudy-DE
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