In 2024, AM Solutions – 3D post processing technology presented a development stage for automated unpacking and powder preparation for the first time, created in close collaboration with EOS, one of the world's leading providers of industrial 3D printing technology. A year later – just in time for Formnext 2025 – it is evident: both systems have impressively proven themselves in beta testing under real production conditions, significantly increasing profitability, efficiency, process reliability, and user comfort.
Formrise tests the F1: Powder preparation as a key process
Formrise from Töging am Inn is the first beta test partner for the new F1 from AM Solutions – 3D post processing technology. The company was specifically looking for a suitable solution for powder preparation – a process that is crucial for the quality of all subsequent steps in additive manufacturing. After each build job, the old powder – depending on the type of powder – must be refreshed with about 30 to 50 percent new powder. If this process is not executed precisely, it can lead to machine downtimes, breaks, uneven surfaces, or color deviations. Errors in this step affect the entire process chain.
Automated, precise, and reproducible
With the F1, AM Solutions offers a 2-in-1 solution that combines sieving and mixing of powder in one system. The mixing ratio between old and new powder can be flexibly and precisely adjusted with a dosing accuracy of ±2%, ensuring consistently high quality.
Previously, the powder was manually weighed and mixed at Formrise using sieve carts – a time-consuming process with a high risk of mismixing or contamination. Assigning an incorrect mixture to a silo could render several hundred kilograms of powder unusable.
The F1 fully automates this critical step. Up to 45 kg of powder can be mixed automatically with this system, allowing for a throughput increase of over 30%. The mixing process occurs in batches of 1.5 kg, significantly reducing mixing time and static charging. The resting time of the powder decreases from two to three days to a maximum of twelve hours. Thanks to the integrated ultrasonic sieve, the proportion of new powder could also be reduced by up to five percent.
Efficiency and growth without additional personnel costs
At Formrise, the F1 is connected to eight printers with different build volumes. At full capacity, about 380 kg of powder is currently needed per week. The operating effort is minimal: after filling the old and new powder silos, all further work steps run automatically. This allows production quantities to increase without requiring additional personnel.
Also, the reduction of the new powder proportion while maintaining consistently high quality lowers the piece costs and simultaneously contributes to a more sustainable use of resources. Additionally, the closed system ensures a high safety standard, as direct contact of personnel with the powder is completely eliminated.
D1 optimizes post-processing in Switzerland
The unpacking solution D1 has also successfully passed its practical test in an industrial environment. A Swiss medical company with more than 10 polymer printers uses the system as part of the beta program to automate manual unpacking and make post-processing more efficient.
Before the introduction of the D1, all components were unpacked manually. With the new fully automatic solution, the pure unpacking time is halved for a full build job with high part density. The operator now only needs to load and unload the system, which reduces labor costs by up to 80% and frees up resources for other tasks. At the same time, productivity increases significantly while piece costs decrease. Additionally, the D1 impresses with particularly innovative, gentle handling of components, ensuring a similarly low rejection rate as with manual unpacking while achieving a significantly more efficient process.
Clean, safe, and flexible in use
The components unpacked with the D1 can be directly transferred to subsequent process steps such as blasting – manual post-processing is not required. The closed process protects employees from powder contact and significantly reduces dust exposure. Furthermore, the D1 allows for individual adjustment of different powder recovery rates, tailored to the respective build job. The intuitive HDMI guides the operator simply and understandably through the unpacking process, while the colored status list always displays the current processing status.
During the test phase, it became evident that the components do not need to cool completely before being unpacked mechanically. Depending on the component geometry and order density, waiting times of eight to ten hours can be saved. The temperature reliably decreases without affecting the components of the system.
Close collaboration in the beta program
The cooperation between the respective test partners and AM Solutions was characterized by intensive exchange. Weekly feedback rounds, software adjustments, and technical support on-site contributed significantly to optimally integrating the systems into the existing production environments. Both beta testers were so convinced by the results that they will permanently incorporate the systems into their production processes.
The practical test under real production conditions impressively demonstrates: The F1 and D1 automate central process steps, increase both profitability and efficiency, and ensure greater safety and reproducibility along the additive process chain. They thus make an important contribution to achieving a fully automated and series-capable production in the SLS area.
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