With the Powder Management System (PMS) and the Direct Feeding System (DFS), AM Solutions - 3D post processing technology expands its solutions for post-processing in polymer 3D printing into a continuous cycle. The new systems automate the return of processed SLS powder to the printing process, closing the existing gap between powder preparation and printer filling. Both systems are now commercially available and will be presented to an international audience for the first time at this year's Formnext.
With the unpacking station D1 and the Powder Handling System F1, AM Solutions - 3D post processing technology already offers established solutions for automated unpacking as well as sieving, mixing, and conditioning (moistening) of polymer powder. However, one process step remained largely manual: The powder processed in the F1 had to be filled into the printing systems via an adapter and by hand. In production environments with multiple systems, this step meant additional effort and brought about avoidable contact of employees with the powder. Accordingly, there was a great need for a continuous automation of powder logistics.
With the newly developed powder management systems PMS and DFS, AM Solutions now closes this process gap. The solutions extend the existing workflow from D1 and F1 into a continuous, automated powder cycle and create the conditions for more efficient and scalable series production in polymer 3D printing. After printing, the components are automatically unpacked in the D1. The recovered powder is then mixed with new powder, sieved, and conditioned in the F1. From there, it is either returned directly to a printer via the Direct Feeding System (DFS) or automatically to multiple printers via the Powder Management System (PMS).
This creates a continuous material cycle from the printing process through unpacking and powder preparation to the renewed supply of the printers. Manual contact with the powder is completely eliminated, operator effort decreases, and process safety, occupational safety, and cost-effectiveness are sustainably improved. Especially in production environments with multiple printing systems, the automated powder supply creates the conditions for more efficient and scalable series production.
DFS: Direct automated powder supply for a single EOS SLS printer
The DFS was developed for the direct supply of a single EOS SLS printer. Together with the AM Solutions F1, it automates the powder supply: The F1 provides the processed powder, while the DFS acts as a valve and distribution unit, taking over the controlled filling of the printer from the connected polybox, where the powder rests. The direct connection is made via a permanently installed pipeline, allowing the powder to be returned to the manufacturing process without additional manual intermediate steps.
The DFS utilizes the existing components of the F1. Additional controls, powder pumps, or media supplies are not required. The system control automatically manages the switch between filling the polybox and the direct supply of the printing system, further increasing the level of automation.
High process safety is ensured by a high-quality, grounded aluminum piping system with optimized pipe bends, allowing reliable material transport over distances of up to 15 meters. The plug-in piping can be flexibly adapted to different hall layouts and significantly reduces installation effort. Integrated sensors and specially designed filling nozzles ensure controlled powder transfer without requiring direct signal exchange between PMS and the printing system.
PMS: Powder supply for up to four EOS SLS printers
The Powder Management System (PMS) was specifically developed for production environments with multiple printers and enables automated supply with processed powder. The intelligent Powder Management System reliably supplies up to four EOS SLS printers with material, thus supporting efficient scaling of additive manufacturing.
Two polyboxes with a usable volume of 180 liters each are connected to the PMS. As soon as one polybox is empty, a valve automatically switches to the second container. The automatic switching between two pre-filled polyboxes ensures continuous powder supply and enables uninterrupted operation, thus increasing productivity. An integrated fill level indicator signals via LED lighting in the barrel and a 360° rotating light when a polybox needs to be replaced or refilled. The system operator thus always has an overview of the available powder supply. The risk of a printer running empty due to lack of material is almost eliminated.
The fully closed system also reduces dust exposure through integrated air recirculation and filtration technology, thus contributing to significantly higher occupational safety. Manual contact with the powder is almost completely eliminated. At the same time, the mobile polyboxes can be easily transported between F1 and PMS and comfortably connected to the Powder Management System.
Automated powder supply proves itself in practice
EOS has already used the PMS under production conditions and has gained initial positive experiences with the automated powder supply. 'The PMS allows our customers to efficiently supply up to four EOS polymer systems with powder with minimal operator effort. The intuitive operation and closed loop make everyday production easier and safer - another advancement from our close collaboration with AM Solutions,' says Magdalena Schwangler, Senior Product Manager Polymer at EOS.
The DFS has also already proven its practicality: At AM Solutions, the system has been successfully in use for about ten months in combination with an EOS P3 NEXT and the F1 in internal production operations. 'The DFS automates the direct powder supply of the printing system and thus significantly reduces manual interventions in the material flow. In daily production operations, it is evident that the combination of F1 and DFS allows for reliable and comfortable supply of the printer and significantly reduces manual effort in powder supply,' says Ann-Kathrin Mahr, Development Engineer at AM Solutions.
World premiere at Formnext
With PMS and DFS, AM Solutions expands its portfolio in the area of powder handling to a fully integrated process chain - from automated unpacking through powder preparation to the automated return of material to the printing process. The two systems close a central automation gap in polymer 3D printing and support users in making their additive manufacturing more economical, reproducible, and scalable.
Both systems are now commercially available. At this year's Formnext, AM Solutions will present the new solutions for the first time to an international professional audience and demonstrate how a continuous, automated powder cycle can be integrated into industrial production environments.
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