AM Solutions has introduced the Powder Management System (PMS) and the Direct Feeding System (DFS) to 'expand its post-processing solutions for polymer 3D printing into a full closed-loop process.'
The new systems automate the replenishment of printing systems with processed SLS powder, closing the gap that previously existed between powder preparation and printer powder supply. Both systems have been made commercially available immediately and will be presented at this year's Formnext.
AM Solutions has endeavoured to automate the manual process of powder transfer to reduce labour and increase safety. With the newly developed PMS and DFS systems, AM Solutions believes it has extended the existing workflow of its D1 Unpacking System and F1 Powder Handling System into a fully automated, closed powder loop, 'creating the conditions for more efficient and scalable series production' in polymer 3D printing.
After printing, parts are automatically unpacked in the D1. In the F1, recovered powder is mixed with new powder, then sieved and powder conditioned to the required quality. From there, it is returned either directly to a single printer via the DFS or automatically distributed to multiple printing systems via the PMS. This, AM Solutions says, creates a continuous material loop spanning the printing process, unpacking, powder preparation, and the resupply of printing systems. Manual contact with the powder is said to be eliminated, operator effort is reduced, and process reliability, occupational safety, and cost-effectiveness are 'sustainably improved'. In production environments with multiple printing systems in particular, automated powder supply establishes the conditions for more efficient and scalable series production.
AM Solutions developed the DFS to provide direct powder supply to a single EOS SLS printing system. In combination with the AM Solutions F1, it automates the powder supply: The F1 supplies the processed powder, while the DFS acts as a valve and distribution unit, controlling the transfer of powder from the connected Polybox, where the material is stored, directly into the printer. The direct connection is established via a permanently installed piping system, allowing the powder to be returned to the production process without any additional manual steps.
The DFS utilises the existing components of the F1 with no additional controls, powder pumps, or media supplies required. The system control automatically manages the switchover between filling the Polybox and directly supplying the printing system, further increasing the degree of automation.
A high-quality, grounded aluminium piping system with optimised bends ensures reliable material transport over distances of up to 15 meters. The plug-in piping system can be flexibly adapted to different production layouts and significantly reduces installation effort. Integrated sensors and specially developed filling nozzles ensure controlled powder transfer without requiring direct signal communication between the PMS and the printer.
The PMS, meanwhile, was developed specifically for production environments with multiple printing systems and enables automated supply of processed powder. The intelligent Powder Management System supplies up to four EOS SLS printers with material, supporting efficient scaling of additive manufacturing.
Two Polyboxes, each with a usable volume of 180 litres, are connected to the PMS. When one Polybox is empty, a valve automatically switches to the second container. This automatic switchover between two pre-filled Polyboxes ensures a continuous powder supply, enabling uninterrupted operation and thus increased productivity. An integrated fill level indicator signals via LED lighting in the drum as well as a 360° beacon light when a Polybox needs to be replaced or refilled. The system operator is thus provided with a constant overview of the available powder supply. The risk of a printer running out of material is virtually eliminated.
The fully enclosed system additionally reduces dust exposure through integrated air recirculation and filter technology, contributing to a significantly higher level of occupational safety. Manual contact with the powder is almost entirely eliminated. At the same time, the mobile Polyboxes can be easily transported between the F1 and the Powder Management System.
EOS has already deployed the PMS under production conditions and gained initial positive experience with automated powder supply, while AM Solutions has deployed the DFS for internal production operations for approximately ten months in combination with an EOS P3 NEXT and the F1.
“The PMS enables our customers to supply up to four EOS polymer systems with powder cost-effectively and with minimal operator intervention. Its intuitive operation and closed-loop system make day-to-day production easier and safer. It’s another step forward made possible by our close collaboration with AM Solutions,” said Magdalena Schwangler, Senior Product Manager Polymer at EOS.
"The DFS automates the direct powder supply to the printing system, significantly reducing manual intervention in the material flow. Day-to-day production operations have shown that the combination of F1 and DFS enables reliable and convenient printer supply and substantially reduces the manual effort involved in powder supply," added Ann-Kathrin Mahr, Development Engineer at AM Solutions.
