Category: Blog

The traditional approach to PolyJet support removal is not optimized for today’s additive manufacturing world. If the bulk of your PolyJet support removal is still done by hand or with outdated equipment, you likely deal with unnecessarily long wait times and warped or inconsistently finished parts. You deserve a support removal solution that’s conducive to softer materials and parts with more complex internal channels. At PostProcess, we are solely focused on solutions that solve additive manufacturing’s post-printing bottleneck problem.

Three factors set us apart from others in the post-printing industry. Our comprehensive solution to PolyJet post-printing includes:

• Cutting-edge AUTOMAT3D™ software allows you to control algorithms that enable you to manage and optimize the process easily.
• Our Submersed Vortex Cavitation (SVC) technology fully submerges parts and print trays to enable our chemistry to access complex geometries.
• Exclusive additive-formulated chemistry provides a safer work environment with minimal waste handling.

Our automated and intelligent solution is trusted to tackle all of your PolyJet support removal needs. By unlocking your full potential for PolyJet 3D printing, you can scale your operations exponentially. Check it out:

• Reduced Labor & Operator Error with a simple, software-controlled, intuitive interface. AUTOMAT3D®, the software behind our technology, utilizes sensor monitoring for agitation control that can reduce breakage PolyJet rates to as low as 0.1%.
• Increased Throughput by more than 30% compared to traditional manual water blasting, making the PostProcess PolyJet support removal the fastest system on the market.
• Advanced Process Controls utilize the technology  to control multiple energy sources to optimize PolyJet support removal. This is essential for parts that have very complex intricate details or very thin and fragile walls.
• Increased Consistency & Reduced Damage through our SVC technology’s pump scheme that ensures “parts that float sink, and parts that sink float.” In other words, regardless of density or geometry, SVC will ensure that the part is uniformly exposed to the detergent and cavitation from the ultrasonics, enabling a uniform finish.

Need more convincing? Protolabs is one of the many companies that realized significant and quick return-on-investment with a PostProcess support removal solution, reducing labor time by 50% and effectively freeing up 20 valuable labor hours per week. Read more about their experience here.

Ready to learn more? Discover the ideal solutions for PolyJet support removal here.

-> Want to connect? Contact Us

-> Return to Blog Homepage

New year, new you. The new year is a great time to reflect on your upcoming goals for the new year. Innovations within the additive manufacturing market will continue to move us into industry 4.0. What’s your game plan for the next 12 months? Our 3rd Annual Post-Printing Survey Report may help shed some light on a few goals for the upcoming year. If you need some ideas for your own additive manufacturing workflow, here are five things to add to your to-do list for post-processing in 2022.

1. Consider EH&S Concerns When You Select a Post-Processing Method

Environmental, health, and safety concerns are more and more critical in the workplace. Many manufacturers are more aware of the impact of their work environment on their employees. In fact, 60% of respondents are looking to improve their post-processing operations’ health, safety, and sustainability. It’s essential to keep your employees safe during the printing and post-printing process.

Traditional post-processing can create hazardous environments. For example, some methods use IPA to help clean the part, which can be a severe environmental hazard with its low flashpoint. To create a safer environment, a 2022 goal may be to reduce, if not eliminate, your usage of IPA in post-printing and PostProcess can help. Our solutions process parts with a higher flash point, reducing the risk to both your lab and everyone working in it.

2. Reduce Your Post-Printing Costs

Did you know: some additive manufacturers are spending as much as 30% of their total part cost on post-processing alone? Or that 20% of manufacturers are unaware of the cost of their post-processing? But it doesn’t need to be this way.

2022 offers an opportunity to evaluate all your post-processing options find a better alternative to your current methods. Chances are there are better alternatives that can help save you money and increase your throughput. Automation is one way to revolutionize your post-processing. Don’t believe us? Check out our case study on Enhancing Resin Removal for SLA Additive Manufactured Parts.

3. Plan to Finish Your Parts Faster

Post-processing in additive manufacturing can be labor-intensive and take a significant amount of time. Our survey found that the #1 pain point three years running across all print technologies is the time to complete parts. This can include anything from manual support removal with tools to hand-sanding surface finishing.

When evaluating your post-printing solution, assess how much time employees spend when they manually finish parts. Ask yourself questions like: Is there a better way to complete the task? Are there alternative ways to process the part? Can we increase throughput and decrease the time spent finishing each part?

In case you didn’t guess, there is a better way to complete post-printing solutions that takes into consideration software, hardware, and chemistry. Read testimonials from customers for real-life examples of how PostProcess decreased their overall post-processing time.

4. Integrate Automation Into Your Post-Processing

2022 could be the year to evaluate your post-processing. Traditionally, manufacturers had to have technicians take hours to finish parts via hand sanding and manual support removal to create the end-user part. This is time-consuming, costly, and can lead to broken or inconsistent parts.

However, your post-printing time and labor could be reduced significantly by automating the process. Check out some of our case studies to discover how customers are taking advantage of automated post-processing solutions.

5. Plan for Post-Prrocessing in Your Design Phase for FDM

Our survey revealed the most popular type of 3D printing is still material extrusion (73.2%). Specifically, with FDM, many manufacturers struggle with consistency and the time it takes to finish parts. But did you know you can help alleviate some of these concerns before your print process even begins?

Our white paper discusses further the value of a DfAM centered approach technique for FDM 3D printed parts like material selection, part orientation, self-supporting angles, and contour toolpaths. Taking these techniques into consideration can reduce time, cost, and even material savings to revolutionize your post-printing workflows.

If you’re ready to evaluate your post-printing process in 2022, be sure to reach out to us here at PostProcess. Our intelligent post-printing solutions offer a comprehensive, data-driven system that delivers transformative benefits for additive manufacturing post-printing – patent-pending Hardware, proprietary Software, and additive formulated Chemistry. We have a range of automated and intelligent solutions that will provide unparalleled support removal and surface finishing to your 3D printed material.

-> Want to connect? Contact Us

-> Return to Blog Homepage

The Proven Resin Removal Detergent: PLM-403-SUB
PostProcess Technologies’ PLM-403-SUB is the world’s only detergent specifically developed for resin removal on 3D printed photopolymer parts. As an instrumental element within several PostProcess solutions, PLM-403-SUB is an effective alternative to solvents like isopropyl alcohol (IPA) and tripropylene glycol monomethyl ether (TPM) for resin removal in SLA, DLP, and CLIP print technologies. Recently, this detergent has officially been recognized as compliant with ISO standard 10993 for the evaluation of biocompatibility by Toxikon Corporation. What exactly does this mean for the proven detergent?

With this new demonstration of compliance with requirements for biocompatibility, additive manufacturing users can enjoy the Submersed Vortex Cavitation (SVC) solution’s new industry standard for maintaining or seamlessly incorporating fully biocompatible processes. Particularly, this will prove impactful for those in the dental, medical, and even audio realms, as materials with applications that come in direct contact with the human body are under ISO 10993: Biological Evaluation of Medical Devices.

In compliance tests, parts were printed with biocompatible Formlabs Surgical Guide resin, and cleaned with PLM-403-SUB. When evaluating for cytotoxicity, sensitization, and irritation, the test articles elicited no reaction with any subjects, making them successfully compliant with requirements for biocompatibility approval of medical devices per ISO 10993.

More on This Proven Detergent
This detergent plays a significant role in PostProcess’s patented SVC technology, combining with software intelligence and a vortex pumping scheme to ensure that 3D printed parts are uniformly, consistently, and reliably exposed to detergent and cavitation. As a result, parts are finished precisely and consistently, requiring little to no manual labor.

Though the overall SVC solution bolsters a safer workflow thanks to minimized manual labor, this detergent has enhanced safety features like a high flashpoint (220°F, 104.4°C) which categorizes it as a non-flammable liquid. The new compliance rating furthers the detergent’s standards of safety. Thanks to the automated nature of the solution and the long-lasting life of the detergent (PLM-403-SUB has significantly better longevity [capacity by weight of resin in solution at 10 minutes] than all other typical solvents [i.e., IPA, DPM, TPM] used to remove uncured resin from printed parts), this technology is renowned for providing a safer, more efficient post-printing process that will remain sustainable even as production volumes scale.

Achieving this compliance perpetuates PostProcess Technologies’ dedication to the seamless integration of their automated solutions and an overall more streamlined additive workflow. For more on our mission to equip additive for Industry 4.0, visit our “Why PostProcess” page.

-> Want to connect? Contact Us

-> Return to Blog Homepage

Even in the technology boom of the 21st century, there is something cutting-edge about additive manufacturing. To those not in the industry, the process of seamlessly designing a part using CAD software, and bringing it to life with a 3D printer in a matter of hours, seems so innovative and streamlined that it could be pulled from a science fiction novel. While the design and printing steps are renowned for ease of use in this way, the same cannot be said for the post-printing step. The post-printing process is rightfully perceived as difficult, as it traditionally abounds with tedious manual labor, the need for hazardous chemicals, and the potential for part breakage.

PostProcess’s solutions were the first in the market to bring digitization and ease-of-use to the post-printing step. Now trusted by customers in virtually every industry, we’re focused on ensuring that integration of automated post-printing is as seamless as possible, with a minimal learning curve. Here’s just a few of the many ways we do just that:

1) User Friendly, Intuitive Software
The driving force in every PostProcess solution, regardless of the technology it leverages, is software. Obviously, the software aspect is what effectively digitizes post-printing, turning it into an intelligent process. The software component works with the machine’s hardware and chemistry to deliver unmatched results through precision energy management, ensuring consistency and reducing the need for trial and error in the finishing step.

The software is developed with data collected from hundreds of thousands of benchmark parts, of all 3D print technologies and a variety of materials. With this repository of built-in data, the solution optimizes software parameters while monitoring saturation, reacting to key process factors in real-time. Thanks to the ability to intelligently generate tailored recipes, these technologies continually ensure a precise finish.

We pride ourselves on maintaining a user-friendly interface for users and thoroughly training customers on every software update. Equipped with presets or the option to customize parameters, the software is developed to reduce operator attendance time, enabling scalability and volume production printing. Plus, users can enjoy peace of mind knowing that the solutions feature built-in maintenance management alerts and notifications sent directly via SMS or email.

2) The Installation, Training and Integration Process: A White Glove Experience
From the time of purchase, the PostProcess team works with you to ensure a solution installation that is as seamless as possible. With full access to our User Support Site including interactive manuals and solution-specific videos, you’ll go in knowing exactly what to expect at your Installation, Training and Integration (ITI).

When you invest in a PostProcess solution, you are not only investing in a product, but in a total solution backed by a reliable team. For the ITI, our expert Applications Engineers (AEs) will arrive on-site to install your new solution. Throughout the process, the AEs will fully train your team on the ins and outs of the technology (including software and maintenance features). During the “Integration” phase, our team will run parts with you, explain best practices, and walk you through the impact that automated post-printing will have on your workflow, from increased throughput to improved end-part consistencies.

From the ITI onwards, you’ll have a direct line to your AE, as well as 24/7 access to our User Support resources. We make dependability a priority, and are always there to answer your questions and help resolve potential issues in a timely manner.

3) Service Plans Built To Fit Your Operation
The service doesn’t end after the ITI. Once the solution is integrated into your additive workflow, you can select from a portfolio of expanded service contract options to ensure you receive the level of support best tailored to your organization’s needs. These plans include hardware coverage, unlimited phone and email support, unlimited application support/software recipe creation, and varying frequencies of onsite visits for training, software upgrades, and preventative maintenance visits.

We’re proud to be driving the future of additive manufacturing by digitizing the art of post-printing into the science of tomorrow, and ensuring implementation is seamless. Take the first step in fully digitizing your additive workflow, and contact us today.

-> Return to Blog Homepage

It’s no secret that Carbon® is one of the world’s leading names in additive manufacturing. Their proprietary Carbon Digital Light Synthesis™ (Carbon DLS™) photopolymer 3D printing process is globally renowned for its ability to produce high-performing consumer and industrial parts at production volumes. As a leading 3D printing company, new opportunities for improved scalability continue to grow. Seeing the opportunity to offer increased productivity and improved end-part consistency to their users, Carbon paired up with PostProcess Technologies to develop an automated resin removal solution for the Carbon ecosystem.

A Custom Solution for Carbon
The resulting solution, now released, is the PostProcess® DEMI 910™. At the core of the solution is PostProcess’s signature patented Submersed Vortex Cavitation (SVC) technology. This technology employs multiple automated energy sources like a vortex pumping scheme and software-driven ultrasonics to finish Carbon parts effectively, in as little time as possible.

What makes this solution exclusively suited for the Carbon L1 printer and M2 printer? The true differentiating point is in the proprietary fixture design. The DEMI 910 is built with a fixture suited to support the exact specifications of the L1 and M2 build platform. This means the solution can seamlessly wash an entire build from a Carbon L1 printer, or two build platforms from a Carbon M2 printer, without ever having to remove printed parts from the build tray. This ergonomic feature improves productivity for technicians and further lessens post-print cycle times.

Leveraging Chemical Energy
In terms of chemical energy sources, the DEMI 910 will be outfitted with a Carbon-specific resin removal detergent, proven for effective use on Carbon EPU 41, EPX 82, MPU 100, RPU 70, RPU 130, DPR 10 and UMA 90 as well as LOCTITE® 3D IND 405 Clear certified for Carbon printers. Developed by our in-house PhD chemists, PostProcess’s resin removal detergents are formulated especially for additive manufacturing and created to be more sustainable than traditionally-used solvents like isopropyl alcohol (IPA).

Compared to IPA, this detergent has outstanding longevity, equating to more infrequent detergent change-outs. A higher flashpoint also makes the detergent less hazardous to work around. The PostProcess team took care to ensure the chemicals would be pleasant to work with. So, this detergent carries a lower vapor pressure and overall more enjoyable scent than something like IPA.

Driven by Data Intelligence
The effectiveness of the Submersed Vortex Cavitation (SVC) technology is driven by our proprietary AUTOMAT3D® software. At the core of this software design is data collected from hundreds of thousands of benchmark parts of all 3D print technologies and most print materials. With this data, the DEMI 910 optimizes recipes, and works with sensors that allow for real-time adjustments of the system’s Agitation Algorithms. Together, these functions allow customized parameters to intelligently tailor resin removal for the unique needs of each part.

We are excited to partner with a company that’s equally invested in innovating scalability for the data-driven future of additive manufacturing. We look forward to the continuous collaboration, and further aligning our full-stack solutions to Carbon’s ever-growing resin and printer portfolio.

-> Download the DEMI 910 Spec Sheet

-> Join our upcoming Webinar on June 22

-> Return to Blog Homepage

Photopolymer 3D printing is one of the oldest and most popular additive manufacturing technologies, though traditional methods for the post-print resin removal step are some of the most cumbersome in all of AM.

Fortunately, automated resin removal solutions built on innovative technology approaches are now replacing archaic resin removal methods for SLA, DLP and CLIP printed parts, and bringing automation to post-printing.

The most salient way to understand the benefits of how an intelligent approach can deliver transformative benefits is to explore how this trusted technology has already enabled different additive operations:

• Splitvision – A Swedish production development company employing additive
• Print Parts – A 3D printing service bureau in Manhattan, NY
• Empire Group – A Massachusetts – based rapid prototyping and industrial design group

Check out the synopses below and read the stories in full in our Case Studies Library.

Splitvision
Primary Pain Point – Integrity of Fine Feature Details
Though they’ve been operational for more than three decades, Swedish industrial design agency Splitvision is relatively new to additive manufacturing, having just recently acquired a Figure 4® Modular vat photopolymer printer. Before dipping their toe into additive, Splitvision typically made their prototypes from polyurethane (PU) foams or solid plastic materials, and often had to outsource when it came time to develop more intricate pieces.

Though the Figure 4 printer allowed Splitvision to develop more intricate builds in-house, the time it took them to manually clean resin off of fine feature detail parts drove up unit costs. They were also troubled by the strong smell of IPA, and its flammability risk. These issues drove them to incorporate an automated PostProcess solution into their additive workflow. In addition to enjoying a safer working environment, they’re able to be more efficient, as the resin removal cycle time never exceeds 10 minutes, and upholds the integrity of fine details. Learn more about the benefits of this new approach with a safer and more sustainable technology in this Application Note.

Print Parts
Primary Pain Point – Throughput
When Print Parts was contracted by New York State to rapidly develop 1 million nasal swabs in response to the COVID-19 pandemic in March 2020, they found themselves expanding their lab with 10 new Digital Light Processing (DLP) printers. To meet their production goal of 250,000 swabs per week, cleaning swabs in multiple IPA baths with just two technicians working at a time wasn’t going to cut it.

Print Parts realized they needed to process multiple batches simultaneously, and that the PostProcess™ DEMI 800™ was the only solution that would let them do it. Thanks to the effectiveness of the ultrasonics and proprietary chemistries, resin could be removed from the swabs in as quickly as 90 seconds, compared to 12 minutes in IPA.

By switching gears to emergency supply production, Print Parts was able to realize the continuous benefits of the SVC technology and automated resin removal capabilities. The service bureau was in the midst of a scale-up, so enabling throughput has remained invaluable to the growing company.

Empire Group
Primary Pain Point – Integrity of Fine Feature Details
As experts in rapid prototyping for more than 20 years, Empire Group was an early adopter of stereolithography (SLA) 3D printing. While Empire Group underwent rapid scaling with the addition of several new printers, they feared that the time spent to manually finish the escalating number of printed parts would slow down their workflow.

Instead of letting post-printing times get the best of them, Empire Group utilized the PostProcess DEMI 800 to reduce their SLA resin removal times by as much as 50%. Plus, thanks to the impressive longevity of the PostProcess detergent used in the DEMI 800, Empire Group wastes less time on chemical changeouts, too.

Want to learn more? Check out a recent article in Additive Manufacturing Media exploring how this technology achieves heightened safety and sustainability for resin removal.

-> Let’s connect! Contact Us

-> Return to Blog Homepage

Out of all of the 3D print technologies on the market, Fused Deposition Modeling (FDM) takes the cake regarding cumbersome surface finishing. Surface finishing FDM parts is notoriously difficult on account of persistent, pesky issues like layer lines and seams. However, by taking the time to be strategic about how you print, you can proactively facilitate your FDM surface finishing process with design considerations. It always pays to think ahead!

Read on for our top five recommendations for the “smoothest” (pun intended) FDM surface finishing process possible.

1. Print Orientation
For optimal end part results, you’ll want to do minimal hands-on surface finishing, and print off a part that is as close to complete as possible. To achieve this, consider the difference that using contour tool paths as opposed to raster tool paths make.

Though it may seem counterintuitive because of how much faster raster tool paths print, the rule of thumb for improved surface finishing is to use contour tool paths on as many exterior surfaces as possible. Raster tool paths almost always take longer to surface finish and leave behind an eminently subpar end result.

In the image shown here the top vacuum part is printed with contour tool paths in a horizontal orientation, while the bottom was printed using raster tool paths in a flat orientation. While the difference in surface finish quality is obvious, you may also be surprised that, when considering total part-in-hand time, the top part has an overall shorter cycle time.

2. Seam Placement
Of course, the main hindrance of FDM is its need to start and stop printing at each layer of a part, thus forming troublesome seams. However, to mitigate the amount of work that must be put into sanding off seam lines, you can think strategically about seam placement while designing your part. The location of your seam can easily be changed within the slicing software. Popular methods to minimize the visibility of seams include placing them along the bottom of the part, as well as spreading them out across the part.

3. Material Selection
Most of the time, print material section is driven by requirements such as strength, chemical/temperature resistance, and even color. While virtually all materials used in FDM printing surface finish well, softer thermoplastics tend to finish faster. For example, PostProcess’s automated surface finishing machines – the RADOR and DECI Duo, can effectively finish a soft material like ABS much faster than a harder, stronger material like Ultem.

4. Printer Slice Height
Depending on the FDM printer and material, you can choose from various preset slice heights ranging from 0.005″ to 0.013″. In some cases, the thinner the slice height, the better your surface finish will be on the Z-axis of the build. The caveat is that thin slice heights often require longer print time.

5. Part Fill/ Contour Passes
If you’re familiar with FDM technology, you’re aware that parts can either be printed as solid or sparse fill. Sparse fill parts reduce internal density, save on material used, and shorten print time, but lack the strength and resistance that solid parts are equipped with. It’s important to keep the fragility of sparse fill parts in mind when surface finishing, and to decipher if a sparse fill part is worth risking breakage during surface finishing.

To strengthen a sparse fill part, you may want to consider adding additional contour toolpaths to prevent possible issues like breakage, delamination, and the exposure of internal raster tool paths.

To minimize or even fully eliminate hands-on surface finishing, check out this video on our Suspended Rotational Force (SRF) automated technologies for FDM. If you’re printing with FDM and are eager to reduce your time spent on support removal, explore our blog post on DfAM: How to Reduce Support Removal Time for FDM. Learn more about the technologies for automated your FDM post-printing operations and how you can achieve dramatic improvements to your workflow here.

-> Want to connect? Contact Us

-> Return to Blog Homepage

Additive manufacturing users – when is the last time you considered just how intensive your resin removal process is? To give you an idea of the resources that you may be wasting by utilizing traditional chemical detergent solutions, we’ve leveraged data from a real-life customer to delve into how our full resin removal solution compares to IPA for resin removal.

The Realities of Traditional Detergents
The shortcomings of using solvents like isopropyl alcohol (IPA), dipropylene glycol methyl ether (DPM), or tripropylene glycol methyl ether (TPM) may be glaringly obvious day in and day out. It’s no secret that these detergents can be cumbersome to otherwise smooth-running SLA, DLP, or CLIP workflows thanks to harmful fumes, low flashpoints, and/or the need for frequent chemical changeouts.

Not only do these detergents often pose a risk to workplace safety, but particularly on complex geometries, they don’t excel at fully removing resin from printed parts. PostProcess customers like Splitvision have complained that in intricate crevices like screw towers, small slots, and ribs, “It can be a very tedious job to fully clean the resin off of these features with a traditional solution like isopropyl alcohol (IPA).” When IPA performance falls short, excess manual labor is often required. Spending time manually scrubbing and picking off resin does not only slow down production, but it can skyrocket the unit cost of a part.

But – what’s the alternative to soak tanks with detergents like IPA?
PostProcess’s latest resin removal detergent, PLM-403-SUB, was developed specifically to work with the brand’s patented Submersed Vortex Cavitation (SVC) technology, a transformative post-printing solution. The SVC system leverages software-driven ultrasonic cleaning, agitation, and controlled temperatures in a vortex pumping scheme to remove resin quickly and efficiently. When used in one of our SVC-based solutions (e.g. the PostProcess DEMI 400 Series), the detergent unlocks revolutionary benefits and efficiencies for SLA/DLP/CLIP users.

Read on for actual data we’ve calculated from a PostProcess customer that demonstrates how our solutions directly compare to IPA.

Lower Flammability Risk
The PLM-403-SUB detergent has a high flammability point, which means it does not ignite from a spark at the machine’s working temperature. Its flashpoint is significantly higher than that of IPA, and it lacks the overpowering, unpleasant fumes that IPA is also notorious for.

Disposal Cost Savings
As we’ve spoken to, PLM-403-SUB is generally less hazardous than IPA, making it comparatively more pleasant to work with, and cheaper to dispose of. In fact, we’ve found that additive users can achieve over 75% or more savings in annual detergent disposal costs when replacing IPA with the whole PostProcess solution.

Longevity and Subsequent Cost Savings
In the customer case being analyzed, PLM-403-SUB lasted five times longer than IPA. Thanks to this longer detergent lifespan, they only went through about 200L of the PostProcess detergent in a year, compared to the 1000L of IPA they typically went through in twelve months’ time. These various savings all piled up to a significant 30% reduction in total yearly resin removal detergent costs.

Because the PostProcess solution is automated and extremely effective, the need for manual labor and hands-on technician time is virtually eliminated. The solution’s intuitive settings allow users to simply “press play and walk away”, enabling rapid processing times without having to run multiple chemical baths.

We’re proud to say that our resin removal solutions have brought these sorts of astounding efficiencies to a variety of additive users, including Empire Group and Print Parts. Most recently, our SVC-driven DEMI 400 Series was selected by German distributor ProductionToGo to pair with their Nexa3D photopolymer printers, offering complete workflow automation. These solutions will enable Nexa3D prototypes or series production parts to be finished with the industry’s fastest cycle time using minimal manual labor, and with detergents that are much less hazardous than other solvents. Read more on this recent partnership here.

-> Want to connect? Contact Us

-> Return to Blog Homepage

Now that you’ve made an investment in 3D printers and design software for your additive manufacturing operation, your print volumes are undoubtedly scaling at a brisk pace. While the rapid throughput that 3D printing enables can boost your business, the post-printing step often falls short at keeping up with this newfound level of productivity. Unfortunately, bottlenecks in this stage are extremely common, as typical post-printing methods are archaic and overly reliant on manual labor.

The answer to this common conundrum? Digitalization. Software-driven solutions can bring your post-printing process up to speed with the rest of your workflow and connect the digital thread. So, where should you get started?

Getting Started with Automated Post-Printing
Our cutting-edge solutions are the first of their kind to effectively replace common support removal methods with automated approaches that leverage patent-pending software and exclusive chemistry technologies. This blog offers helpful insight into the differences between the various PostProcess technologies, as well as which technology is most ideal for removing structural part supports in your unique workflow. We’ll be touching on two popular print technologies, Fused Deposition Modeling (FDM) and PolyJet.

So, how do you know which of our support removal solutions is best suited for you? Of our four core technologies, two are developed for support removal:

• Volumetric Velocity Dispersion (VVD)
  The patented approach utilized in our VORSA and BASE solutions.
• Submersed Vortex Cavitation (SVC)
  The patented approach utilized in our DEMI 400, 800, 900, and 4000 Series.

Both of these approaches utilize our AUTOMAT3D® software to customize parameters to your unique processing needs, which may then be saved as “recipes” for future use. Each option also leverages detergents specific to whichever primary polymer-based print technology you’re utilizing – material extrusion (i.e., FDM) or material jetting (i.e., PolyJet). In fact, the print technology that you’re using is going to be the most crucial deciding factor in determining if VVD or SVC is the best fit for you.

Fused Deposition Modelling (FDM)
FDM is renowned for its versatile ability to seamlessly print complex geometries. Our VVD technology is developed for the post-printing needs of intricate FDM part geometries and meant to effectively replace submersion tanks. Due to limited ultrasonics capability and temperature control, processing times in these traditional submersion tanks are often lengthy and inefficient. VVD abounds with benefits to improve FDM post-printing workflows.

• The technology employs spray nozzles that release detergent in a high flow, low-pressure technique. Combined with heating/cooling agitation, these parts remove hard-to-reach support material on FDM parts gently and efficiently.
• The spray technique of VVD prevents sparse-fill FDM parts from becoming waterlogged, allowing rates of removal to remain optimal.
• While alternative post-printing detergents are often caustic and require frequent changing, PostProcess’s proprietary detergents used with VVD can process parts 10-12x as quickly and last twice as long as the leading FDM post-print detergents.
• Companies that have implemented VVD solutions such as the BASE have experienced significant returns-on-investment, such as decreases in operator labor and a drop in the time that must be dedicated to post-printing. For example, The Toro Company averaged an 89% decrease in post-print processing times and over a 90% decrease in operator labor. Read the full case study here.

PolyJet
As PolyJet printing is especially conducive to softer materials and parts with more complex internal channels, our SVC technology is ideal for effectively breaking up and removing support material without disfiguring PolyJet parts. Traditional PolyJet support removal methods like water jetting and submersion tanks are notorious for slow-moving processing and causing damage to parts.

• SVC is our proven technology for PolyJet post-printing. Leveraging submersion techniques rather than spray methods, the technology employs a combination of heat, pump agitation, and ultrasonics to finish PolyJet parts.
• While tacky hybrid layers on PolyJet parts can be bothersome to post-print, SVC can swiftly remove this layer in a singular step.
• With agitation-driven submersion, SVC technology can more easily access the intricate internal channels of PolyJet parts. These sorts of channels may be especially prevalent in PolyJet parts created for medical or dental applications.
• SVC’s vortex pumping scheme ensures that “parts that float sink, and parts that sink float.” In other words, regardless of density or geometry, SVC will ensure that the part is uniformly exposed to the detergent and cavitation from the ultrasonics, enabling a uniform finish.
• Thanks to the calculated design of the SVC machines, parts can be loaded in and finished while still on the build tray for seamless transport between additive phases.
• As previously mentioned, PostProcess’s proprietary detergents are safer, less caustic, and hold longer lifespans than competing PolyJet detergents.

Protolabs is one of the many companies that realized significant return-on-investment with a PostProcess SVC solution, reducing labor time by 50% and effectively freeing up 20 valuable labor hours per week. Read the full story here.

Still have questions? Our Live Solution Experience tours delve into our solutions for FDM, PolyJet, and beyond. Guided by one of our expert engineers, these tours show parts being processed and our machines being run in real-time, with the opportunity to ask questions.

After You’ve Chosen Your Solution
Once you’ve invested in one of our automated solutions, a PostProcess Application Engineer will guide you through our entire installation, training, and integration (ITI) process. This includes training on the functions and capabilities of the solution and advisement on the best practices regarding the cadence of your maintenance and your revitalized throughput levels. PostProcess has immense experience across virtually every additive manufacturing material, so you can rest assured that our engineers can make recommendations specific to your particular workflow and materials. Additionally, our User Support Site features resources and manuals that are accessible whenever you need them.

Want to learn more? Head over to our comprehensive FAQ page for additional insights, or contact us at info@postprocess.com.

-> Want to connect? Contact Us

-> Return to Blog Homepage

The start of a new year is an opportune time to hit the “refresh” button and take a good look at where improvements can be made. As we look ahead to 2021, most additive manufacturing operations are hopeful to save costs and increase productivity and efficiencies in the upcoming year. One often-overlooked roadblock to achieving these goals can be post-printing.

Often called the “dirty little secret” of additive manufacturing, post-printing is the final phase of the additive workflow that though rarely talked about, can have dire impacts on efficiencies and scalability. As the world’s first innovator of automated post-printing solutions, PostProcess is committed to resolving the issues caused by post-print bottlenecks with proprietary technologies that leverage software, hardware, and chemistry. Read on to delve into the top five post-printing mistakes that additive companies can make, as well as opportunities to overcome them.

1. Underestimating Future Post-Print Needs
Additive is a rapidly scaling industry, predicted to reach a total market size of $26.68 billion by 2027. So, it’s likely that your own additive operation is growing at a steady rate as well. In our second Annual 3D Post-Printing Trends Survey Report, a mere 25% of individuals reported that their current post-printing methods will be acceptable for their future plans. Along the same grain, the respondents using print technologies targeted for production scale were the ones reporting the most expenditures and labor issues associated with post-printing.

A first step in understanding your true post-printing needs is to embrace the integrated ideology that we employ at PostProcess. While it’s easy to put post-printing on the backburner when viewing “Design”, “Print”, and “Post-Print” as separate, sequential phases, considering these steps to be interdependent can help set you up for success and accurately evaluate your post-printing needs. At the end of the day, arcane post-printing steps like manual picking and sanding, or traditional tumbling/blasting are simply not sustainable options for production volume additive manufacturing. Proactively considering your post-print needs are critical in making the most out of your time, energy, and materials.

2. The Impact of EH&S
Our aforementioned trends report study found that Vat Photopolymerization respondents held the highest concern for improving the health, safety, and environmental (EH&S) impact of their post-printing operation, followed closely by Powder Bed Fusion respondents. Considering the hazards associated with current methods, there is plenty of room for improvement in the safety and sustainability of post-printing.

Speaking to these EH&S issues, the chemicals traditionally used to finish 3D printed parts are notoriously harsh, causing unpleasant working conditions for technicians. Additionally, low flashpoints on chemicals like isopropyl alcohol (IPA) carry immense safety concerns and may lead to storage limitation issues. Traditional submersion methods (usually used for Vat Photopolymerization) require somewhat frequent changeouts of these potentially caustic chemicals – effectively slowing down efficiencies, and increasing the risk of safety hazards. The bottom line? Understanding the input and output of each printing system used in a facility can spare you from months of initial downtime and missed opportunities for ROI savings.

If you’re looking to modernize your workflow, PostProcess engineered the first-ever detergent specifically conducive to additive resin removal. Compared to IPA, this detergent immensely improves longevity to better handle large print volumes and was developed with a higher flashpoint to ease storage concerns. After experiencing continuous issues with IPA, international industrial design agency Splitvision switched to our solution which took cycle times from 30 minutes per part down to finishing 10 parts in less than 5 minutes. You can read the case study in full in our Case Studies database.

3. Undervaluing DfAM
Considering the post-print phase during part design can enable significant time, cost, and material savings for additive operations – it’s part of the integrated approach we spoke to earlier. When lacking this mindset, it’s common for engineers to mismatch applications to print technologies, and set unrealistic expectations for how the part will come off the printer. When occurring in real-time, these sorts of surprises can significantly inhibit productivity.

By beginning with the end in mind, technicians can optimize post-printing with simple, intuitive design considerations. Our white paper covers in depth the impact of the ways that strategies like part orientation, self-supporting angles, contour toolpaths, etc. can help impact overall efficiencies in FDM printing. Embracing the full power of DfAM is essential to achieving the highest part quality standards and most efficient operation possible.

4. Overlooking Post-Printing Costs
This year’s trend report found that about 20% of respondents don’t know what they spend on post-printing. These numbers can add up fast, as they incorporate labor, equipment, consumables, and more. Because technicians are typically doing the post-printing and management is somewhat removed, it’s understandable why the impact of these processes get overlooked. By keeping a close eye on the resources that your post-printing utilizes, you can stay aware of potential inefficiencies in your process, and gain a sense of how much you may save with an automated solution.

PostProcess has a specific return on investment (ROI) formula calculation which determines how much post-printing time one of our automated solutions could save an operation. To fully understand the impact of manual post-print costs, it’s essential to refer back to issue #2, and take chemical/general waste output, as well as material scrapping into consideration.

5. Hindering Scale-Up
This issue speaks to the general gist of the problem with traditional post-print methods. Simply put, manual post-printing processes are too time-consuming to truly allow the growth and scalability that most printing companies need to thrive. Not to mention, they can be incredibly wearing on technicians. If you are thinking of scaling up your additive process in 2021, it may be tempting to throw manual labor at the problem. However, the most efficient solution is going to be software-driven, so it’s vital to consider digitalized options.

By automating the post-printing process, technicians can spend less time on manual labor, and more time on sustainable, value-adding tasks. As the manufacturing landscape and specifically additive manufacturing becomes increasingly digitalized, implementing an automated approach to overcome the post-printing bottleneck can be transformative for your additive workflow. For more real-life examples of ways that our technologies have revolutionized additive operations, explore these testimonials.

-> Want to connect? Contact Us

-> Return to Blog Homepage