Author: Solivet

Welcome to part two of the four-part series highlighting each of PostProcess’ core 3D post-printing technologies. In part one, we discussed our VVD technology, ideal for automated support removal on technologies such as SLA, PolyJet, and FDM. In this post, we’ll explore the building blocks of our Thermal Atomized Fusillade (TAF) technology, utilized in our one-of-a-kind Hybrid DECI Duo. TAF technology performs surface finishing allowing for fast cycle times and consistently finished end parts. The key components to TAF are:

• Proprietary detergents
• Suspended solids
• Fusillade jets
• AUTOMAT3D® software

Let’s dive into the role each one of these elements plays in the engineering of TAF technology.

Proprietary Detergents:

The detergent utilized in the DECI Duo is designed specifically by our chemists to optimize the mechanical and abrasive energy that is provided by the suspended solids. So another way to think of it is suspended solid optimization. The detergent helps the suspended solid circulation through the machine and enhances the solution’s capability to finish internal channels while reducing safety hazards associated with dry blast processes. We offer a primary detergent that is effective across a breadth of print technologies offering the freedom to process a variety of materials without swapping detergents.  Additionally, we continuously perform research to optimize each application; our most recent findings on Inconel 718 are available in this recently released white paper.

Suspended Solids:

A suspended solid is a fine particle, either metal or ceramic, that mixes with a detergent to create distinct abrading solutions to improve various surface properties. Our development engineers performed extensive testing on different materials, shapes, and sizes of suspended solids to determine the most effective combination specific to additive manufactured materials. Application dependent, our engineers will help choose the right suspended solids based on the user’s geometry and profile requirements. Together, our suspended solids and proprietary detergents provide the “Atomized” component of our TAF technology. This atomized approach offers flexible and consistent powder removal and surface finishing across a wide range of geometries.

Fusillade Jets:

With our TAF technology, each jet emits compressed air, detergent, and suspended solids at variable software regulated pressures. The two “Fusillade” jets fire either simultaneously or in rapid succession, depending on the Agitation Algorithm setting within the software. The wide range of pressures, typically from 20 psi to 130 psi (138kPa – 896kPa), provides the level of flexibility needed to process materials across all technologies for a variety of finishing requirements. TAF technology uniformly processes a variety of geometries by having two software-controlled jets on single axes spraying the parts fixed on a rotating turntable. One jet is on the top of the machine moving front to back and the other moves up and down. This video animation helps demonstrate the process further.

AUTOMAT3D Software:

Our AUTOMAT3D software acts as the conductor of the whole process, configuring all of the energy output sources in response to sensor input data. AUTOMAT3D is integral in our TAF technology due to the intricacy of coordinating all of the numerous software-enabled energy sources. The software manages temperature, jet movement, turntable speed and direction, fluid and air pressure, all in concert with cycle time. This control over the temperature is the “Thermal” piece of TAF technology. AUTOMAT3D provides the solution with the highest degree of energy management while simultaneously simplifying machine operation. Recipe storage allows for process parameters to be saved for easy recall, requiring minimal operator time and promoting consistency with each cycle. To further minimize downtime, preventative maintenance and warnings allow users to plan ahead of time for maintenance.

Now that you have a better understanding of how our Thermal Atomized Fusillade technology works for surface finishing, find out if it is right for your application!  Contact us today to discuss your specific needs and get the benchmark process started.

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Welcome to the first in our four-part series guiding you through a deep dive into the building blocks of our first-of-their-kind automated support and resin removal and surface finishing solutions 3D post-print technologies. You may know us as the world’s first and only software-driven solution for post-processing of additively manufactured parts for all 3D print technologies. What you may not know is that we have four unique key technologies that harness various chemical and mechanical energy sources that form the basis of all the innovative solutions we offer.

Our four core technologies are:

• Volumetric Velocity Dispersion (for soluble support and resin removal)
• Submersed Vortex Cavitation (for soluble support and resin removal)
• Suspended Rotational Force (for surface finishing)
• Thermal Atomized Fusillade (for excess powder removal and surface finishing)

In a series of four blog posts, we’ll educate you on the building blocks of each technology and relate them to the flashy words our technologies are tagged with. First up is our Volumetric Velocity Dispersion (VVD) technology for support and resin removal, which is used in our VORSA 500 and BASE Solutions.

The key components to VVD are our:

• Proprietary detergents
• Two jet rack manifolds
• AUTOMAT3D® software

Now let’s dive into the role each one of these components plays…

Proprietary Detergents:

Our additive-formulated chemistry is leading the charge, playing a key role in the power of our VVD technology. Unlike anyone else in the industry, our three primary detergents for use in the VVD line were all developed by our chemists specifically for additive materials. We have a detergent specific for each supported print technology – material extrusion (i.e., FDM) and material jetting (i.e., PolyJet). For each one of these technologies, the PostProcess detergent will dissolve the soluble support material or uncured resin without compromising the build material. Our chemistry is optimized for the materials used by each technology, and our solutions then take it a step further by optimizing multiple fine-tuned mechanical energy sources which we will cover in the next section.

The parts being doused in a high volume of our proprietary detergent while processing covers the “Volumetric” portion of VVD technology.

Two Jet Rack Manifolds:

Leveraging spray technology rather than submersion introduces a mechanical energy source that is unique in the industry. PostProcess VVD technology utilizes two jet rack manifolds, the first a bottom-mounted manifold intended for low pressure, full tray coverage. The second top-mounted manifold runs along the top of the chamber. The user may set parameters for varying levels of energy output from the jets via the AUTOMAT3D software for a more focused agitation. Together the two opposing jet streams keep the parts in equilibrium throughout the cycle mitigating the need for fixturing. The mechanical energy from these two streams, flowing at rates upwards of 200 GPM (over 750 liters/minute), optimizes the chemistry by disposing of the support material as it weakens, dramatically accelerating the cycle times. This high volume flow complemented by low pressures (less than 35 PSI, or 241 kPA) remains gentle on part geometries throughout processing. These powerful yet gentle flow patterns are what accounts for the “Velocity” component in our VVD technology.

AUTOMAT3D Software:

At this point, we have covered the hardware and chemistry portion of PostProcess’ VVD technology. Our AUTOMAT3D software is the final and most imperative part of our technology. The acute control of the system’s energy sources is essential to all of our solutions. AUTOMAT3D acts as the conductor of the whole process, configuring all of the energy output sources in response to sensor input data. The software manages the temperature, pH, jet flow patterns, and movement, all in concert with cycle time. This control over the combination of jet usage and movement is the “Dispersion” piece of the technology. Not only does the software provide the solution with the highest degree of energy management, but it also simplifies machine operation for the user. With recipe storage, process parameters can easily be saved for easy recall, requiring minimal operator time and promoting consistency with each cycle. Lastly, preventative maintenance and warnings allow users to plan for maintenance, further minimizing any downtime.

Now that you have a better understanding of our Volumetric Velocity Dispersion technology, find out if it is right for your application! Contact us today to discuss your specific application and get the benchmark process started.

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Metal and metal alloy parts can now be made with near limitless design freedom to high standards using a wide range of metal powders via additive manufacturing (AM). And while prototyping metals with 3D printed technologies has proven quite valuable, it is no longer solely for design validation. It is now being used for the production of components for the most demanding applications in aerospace, automotive, medical, dental, and industrial industries.

This added value does not come without its challenges, however. Many of these challenges appear in the post-print stage after the geometry has been generated in achieving an acceptable finish on the part.

Our latest white paper discussions a novel approach to smoothing the surface profile for one particular metal produced by AM, nickel superalloy Inconel 718. Key considerations reviewed in this paper include part density and hardness, corrosion (chemical) resistance, grain structure, as well as manufacturing factors including the impact of print technology and print orientation on surface profile outcome.

Learn about how combining software-driven automation and a patent-pending chemistry solution dramatically improves surface finish results including reduced technician touch time and increased consistency and productivity.

->Access the White Paper

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Announcing our latest innovation, the new automated and intelligent DEMI 400™ (originally named FORTI) support and resin removal solution. The DEMI 400 leverages PostProcess’ proven submersible technology already available in our DEMI 800 for consistent, hands-free support structure and resin removal on 3D printed PolyJet, FDM, SLA, and CLIP parts. We designed the DEMI 400 specifically to address the growing market demand for a software-driven system smaller than our production-scale DEMI 800™ machine.

Just like its big brother, the DEMI 800, the DEMI 400 is enabled by PostProcess’ patent-pending AUTOMAT3D™ software platform. Designed within our family of submersible support removal solutions, the DEMI 400’s highly engineered Submersed Vortex Cavitation (SVC) technology utilizes advanced ultrasonics, heat, and fluid flow in concert with our proprietary additive-formulated chemistry. An advanced pumping scheme creates vortex action to optimize the rate of removal of the support material and minimize buoyancy issues to virtually eliminate damaged parts. You can learn more about SVC technology in our recent video on the DEMI 800 solution.

With the DEMI 400’s software-driven automation, operators spend less time on tedious, manual support and resin removal and more time on value-added tasks. Utilizing user-friendly controls, throughput will accelerate with the ability to optimize cycles to produce consistent end parts via the system’s pre-designed agitation levels.

Whether you’re printing PolyJet, FDM, SLA, or CLIP parts, find out what the DEMI 400 can do for you and contact us today.

-> See the DEMI 400’s Specifications

-> Check out the full lineup in our Support & Resin Removal Family

-> Learn more about our technology on our Blog

Our most recent Press Release and White Paper address the topic of messy and cumbersome 3D printed SLA resin removal. We set out to achieve the fastest processing times possible with the development of an enhanced formulation of our chemistry, PLM-402-SUB (formerly named PG1.2), combined with our patented SVC technology to achieve unmatched end part consistency and hands-free automation.

This comparison chart is just a sampling of the data presented in the White Paper. The data demonstrates the unparalleled longevity of our PLM-402-SUB chemistry, which provides for resin removal on up to 1000 trays (average tray size = 15″) before reaching saturation. This increased longevity also reduces the costs of waste disposal and machine downtime as fewer detergent changeouts are required. The solution reduces the overall number of steps and chemical applications required from print to finish, driving increased productivity for technicians.

The White Paper explores in more detail how the PostProcess solution achieves the fastest resin removal on the market, cleaning trays of parts in 5-10 minutes, validated in multiple production environment test scenarios with 8 different resin materials.

To learn more, download the White Paper HERE.

Read the press release announcement on this innovation HERE.

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