Month: September 2018

There’s a common misconception that PolyJet Support Material 705 is much more difficult to remove during post-processing than SUP 706.

This may be true when using legacy methods such as water jets, soak baths, or manual labor. The SUP 705 material adheres to the part more firmly, so when applying intense force with these legacy methods, you can easily lop off fragile portions of a print as well as the support material. However, 706 is not without its post-processing challenges as well; you run the risk of being overly aggressive with the softer 706 material and damaging the part or experiencing warping and part absorption by over-saturating them.

In truth, SUP 705 can be just as easily removed as SUP 706 with a different approach – the PostProcess approach integrating software, hardware, and chemistry into a single solution.

Utilizing a data-driven, software-forward solution gives the operator precision control, including the ability to vary parameters such as temperature and agitation level to accommodate the firmer SUP 705 or softer SUP 706. The recipe program feature eliminates trial and error resulting in scrapped parts or inconsistent results – you get the desired finish every time at the touch of a button with the ability to save and recall multiple recipes for your ideal SUP 705 and 706 process parameters.

Our thoughtfully designed hardware platform utilizes agitated flow to effectively remove supports with a ‘sink-float’ process to rotate parts throughout the chamber. This variable motion, combined with optimal energy delivery via ultrasonics, results in fast and uniform hands-free support removal for both SUP 705 and 706. With the motion of fluids within the machine controlled by software, sensor data adjusts in real-time so that parts are not damaged and removal of supports is consistent, regardless of which material.

Designed specifically for PolyJet supports, our chemistry targets removal of support material, leaving build material in perfect condition. Whether for SUP 705 or 706, the same patent-pending consumable does the job. Because our chemistries are already mixed, there is no chance of incorrectly mixing a batch, as compared to other offerings which must often be mixed on-site. Our chemistry utilizes low concentrations of several conventional chemicals in unique combinations, resulting in safe and effective support removal for SUP 705 and 706 in one bottle.

So the next time you sigh at the prospect of removing support on your SUP 705 PolyJet print, remember that there’s a solution that helps you effectively manage both support removal jobs in one system, ensuring unparalleled consistency and unlimited throughput for your PolyJet operation.

To learn more –
– Check out our DEMI 800 support removal solution
– Read our recent White Papers on PolyJet support removal

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This week’s blog post is a timely fit for the many 3D printed metal announcements coming out of the IMTS show in Chicago, such as HP’s unveiling of its MetalJet technology. Today we released our most recent Case Study that demonstrates excellent surface finish standards and replicable results to an exacting requirement for complex metal parts with the automated Hybrid DECI Duo.

This story discusses the transformative outcome with additive manufactured titanium and nickel alloy shrouded impellers for Ingersoll Rand. After parts arrived off the printer with an Ra (roughness average) value that did not meet their specifications, Ingersoll utilized multiple traditional 3D post-printing methods that fell short of their tight tolerance requirements for aerodynamic testing and exacting surface finish needs for aerodynamic performance.

After teaming with PostProcess and utilizing the DECI Duo solution, Ingersoll has obtained consistent, repeatable Ra results for the 3D printed shrouded impellers as proven through benchmark testing. The software-driven, hands-free DECI Duo delivered parts that consistently passed aerodynamic testing with flying colors, with an average of 70-80% reduction in Ra for parts run for 20 minutes or less. While its high quality and consistency requirements led Ingersoll to PostProcess, the ease of operations and cost savings are seen as significant additional advantages.

“We have chosen the DECI Duo because of its repeatability, minimal setup, processing times, and cost of ownership. Photochemical machining, extrude honing, and micro polishing or micro machining all yield very good results when applied correctly, however extensive tooling and equipment costs, setup times, and required DOE’s prior to applying the surface finishing method to obtain a repeatable process have made the DECI Duo a better option.

In addition, some of aforementioned finishing techniques unevenly remove material inside the flow path of the impeller, whereas the PostProcess DECI Duo uniformly treats the entire surface of the flow path. The final geometry of the flow path must remain as unaltered as possible after post-processing of any kind.”

Ioannis Hatziprokopiou
Mechanical Engineer
New Product Development
Ingersoll Rand Compression Technologies & Services

As the market continues to innovate in the 3D printed metals space, more exacting surface finishing results and faster volume throughout will be required. Our Hybrid DECI Duo is up to the challenge and ready to meet the market’s need.

To learn more, download the full case study.

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