AM Solutions has introduced the D3 post-processing system for the unpacking of parts from the EOS P 770 3D printing systems.
It follows the development of the D1 for the EOS P3 Next.
The D3 system has been designed specifically for the ‘high weight’ (up to 90kg) of P 770 build jobs and for ‘future system generations of this size class’, per AM Solutions.
Set to be premiered for the first time at Formnext 2026, the D3 is divided into three stations, with the build job passing through each sequentially within a ‘fully enclosed system.’ At the loading station, the exchangeable frame is loaded from the printer once the build job has cooled to approximately 60°C (unpacking temperatures of up to 100°C are an option ‘under certain conditions’). An electrically driven actuator then pushes the parts along with the powder into a chamber, which then moves into the central process station where it is secured and set in motion on a vibration platform. In the third station, the power discharge station, the powder flows through integrated screens and into the Polyboxes.
At the end of the cycle, the chamber returns to the loading station, and the exchangeable frame base lowers in a controlled manner together with the parts. This allows the parts to return to the exchangeable frame without any drop, where they are ready for removal. For a PA 12 build job, the entire unpacking process takes approximately 20 minutes, depending on build height and packing density.
Laser-sintered parts are typically cleaned of powder using compressed air. The airflow causes the parts to move around vigorously, making them collide with one another and potentially causing damage. The D3 takes a fundamentally different approach, eliminating compressed air from the unpacking process entirely. Instead, it leverages the powder itself: during the first vibration cycle, the powder remains entirely within the chamber and acts as a protective cushion between the parts. This largely prevents friction and contact damage, which is particularly beneficial for delicate geometries. Even during sieving, parts remain nearly stationary, as only the screen surface vibrates in the third station. An additional benefit: by eliminating compressed air during unpacking, the associated energy and operating costs are also avoided.
For robust parts where contact between parts is not critical, the optional “Unpacking Plus” function is available. With this feature, the build job passes through the vibration and powder discharge cycle a second time, releasing additional powder from the part surface for recovery. Operators can thus decide on a part-by-part basis whether maximum part protection or maximum powder recovery takes priority. With “Unpacking Plus”, powder recovery rates of up to 95 percent are achievable, depending on packing density and geometry.
Users of the EOS P 770 expressed the need to collect the thermally less-stressed powder from the peripheral zones of the build job separately from the more heavily stressed powder near the parts. Until now, this required manual effort or was simply not done at all. The D3 addresses this need using the “Unpacking Plus” function as well, but with a shortened first vibration cycle. This initial cycle releases only the peripheral layer powder, which is discharged into a dedicated Polybox. In the second pass, the powder adhering to the part is released using adjusted parameters and directed into a second box. Switching between the two is handled automatically via valve control. This allows operators to selectively return the low-stress peripheral layer powder to the powder loop while treating or sorting out the more heavily stressed powder separately.
"The requirement for powder separation came directly from our customers' day-to-day production environments, and we took it very seriously. What was critical for us was that it works without any additional manual steps and does not complicate the system's workflow," said Alexander Gückel, Project Manager at AM Solutions.
The D3 is operated via a Siemens control panel designed for ease of use. Operators can store custom recipes, adjust vibration duration and intensity, and process build jobs of any height. For cleaning and maintenance, the vibration platform can be removed entirely; multiple access panels provide entry to all relevant areas. Attention has even been paid to the smallest details: when the Polybox connection hose is not in use, a dedicated parking position keeps it securely in place.
D3 is currently undergoing beta testing at FKM Additive Manufacturing. The company is one of Europe's leading providers of industrial additive manufacturing, with extensive production capabilities for both polymer and metal parts. FKM sees particular potential in automating the post-processing of large polymer build jobs to reduce manual workload. “As pioneers in bringing additive manufacturing into industrial production, we continuously challenge existing processes, explore new opportunities, and drive innovation forward,” explains Matthias Henkel, Managing Director of FKM. “In polymer production in particular, unpacking large build jobs, such as those we process on our EOS P 7 series systems, has traditionally involved a considerable amount of manual work. Automation offers several key benefits: it reduces labour requirements and minimises our employees' direct exposure to polymer powder, while also creating a cleaner working environment. Both the compelling concept behind the D3 and our positive experience from many years of working with AM Solutions convinced us to participate in the beta program. Initial feedback has been very positive.”
“Industrial additive manufacturing does not end with the printing process. To maintain productivity and cost efficiency throughout the entire process chain, high-performance peripheral solutions that are optimally aligned are essential. The D3 from AM Solutions is designed to meet the requirements of large-format production systems, making an important contribution to efficient and scalable additive manufacturing,” said Vanessa Seidenschwarz, Head of Product and Program Management Polymer at EOS.
The D3 will be on display live for the first time at Formnext from the AM Solutions – 3D post-processing technology booth in Hall 12, Stand E79.
