Category: Blog

They say study the past to know the future. In the migration from subtractive manufacturing to additive, we may be following the existing paradigm too closely.

Both subtractive and additive manufacturing span a three-step process: part design, part build and the post-processing of the part to make it viable or customer ready. There is a commonality to approach across the three steps in both subtractive and additive. Parts are designed using CAD systems. Those digital files are used to drive the build approach — to design tooling for a traditional (e.g., injection molding) build or to drive the printer in an additive build. Then, regardless of subtractive or additive, manual or mechanical solutions are generally used for post-processing. And that’s a bridge too far.

The power of industry 4.0 rests not with the automation of individual steps in a process. That’s important – but the true power rests in the connective interplay across systems. In manufacturing 4.0, it is not just the gathering of data that is important; it is the connecting of data across smart systems that is transformative. Connected data shifts the factory floor from “merely” better-informed technicians reacting to fresh data (the current step change) to better-informed machines making anticipatory changes based on data long before a technician gets involved. And that’s where additive manufacturing has the opportunity to not just radically distance itself from subtractive – but to also lead the 4.0 revolution.

Today, in both subtractive and additive, the first two steps (design and build) share a common digital thread. CAD files used in design help drive the manufacturing solutions (whether traditional or 3D printers) to build the part. In both cases, the digital thread snaps at post-processing. In subtractive, that’s state of the art. In additive, it’s the tip of the iceberg. The additive opportunity comes alive with the digitization of the third and final step.

Picture this: when you automate the third step you enjoy three immediate benefits. First, unparalleled consistency in the removal of supports and surface finishing on the thin walls, complex geometries, internal channels and fine feature detail unique to 3D printing. Second, faster throughput in processing these complex parts. And third, increased productivity underpinning a rapid ROI on automated post-processing solutions. There are important ancillary benefits as well, from radical reductions in technician attendance time to replicable processing.

But beyond automating – digitizing – the third step transforms the entirety of additive manufacturing. It creates an end-to-end solution in which the digital files used in design and build now feed the automation in the third and final step, post-processing. Moreover, it creates a closed-loop solution in which data from post-processing can be used to feed design and build iterations in real time. Learn about our PostProcess CONNECT3D® software platform in development that leverages existing CAD formats and can propel your additive system closer to 4.0 standards. Additive may just drive the first lights-out transition your company is looking for.

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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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When people who are familiar with additive manufacturing talk about the post-processing step, they usually speak in terms of minimizing the time and labor associated with finishing their parts. Many companies who are new to 3D printing find out late in the game about the additional cost required when parts come off the printer – the industry’s “dirty little secret”. Here at PostProcess, we like to talk in more positive terms about the post-print step. Our mission to digitize post-printing is all about helping customers maximize the opportunity for their business in the post-processing stage with the remarkable ROI possible from our automated and intelligent solutions.

The best way to illustrate ROI is through real-world examples of customer use cases – in this instance, a consumer goods application of PolyJet utilizing our DEMI 800 Support Removal solution. This particular business has the intersecting burden of particularly tedious support removal on delicate parts and a high labor rate.

The PostProcess DEMI 800 is the perfect solution for this situation, as the system’s precision-controlled agitated flow effectively removes supports with a ‘sink-float’ process rotating parts throughout the chamber. This variable motion, combined with optimal energy delivery and chemistry filtration, results in fast and uniform support removal. With the motion of fluids controlled by our Agitation Algorithms within our AUTOMAT3D™ software, sensor data adjusts in real-time so that parts are not damaged and the removal of supports is consistent.

This customer’s ability to process 30 parts in a cycle, while achieving uniform removal of support material every time, made ditching their manual finishing process for an automated solution a no-brainer:

– decreased technician touch time per part 71% from 4 to 1.16 minutes
– reduced total cost per part 77% from $10.00 to $2.31

When we talk about ROI however, it’s more than just dollars and cents. The ability to utilize any one of our systems for multiple print technologies allows customers to streamline their operations. Automation delivers a level of quality and consistency that is simply not possible using manual processes or traditional manufacturing machines, including faster processing times with less or no breakage driving better throughput. Our customers are able to redirect their skilled labor to more valuable and engaging tasks. Additionally, a software-based approach on our production systems provide automated basic maintenance scheduling, which means technicians spend less time on maintenance and have less pressure to remember maintenance schedules. And ultimately, our automated, data-driven approach is necessary to enable additive manufacturing to scale.

Want to learn more about the DEMI 800?
– Learn about how software, hardware, and chemistry work together in this White Paper
– Read this recent blog post on the newest design features of the DEMI 800
– Watch this video on PolyJet Support Removal

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Positive indicators for Additive Manufacturing’s widespread adoption appear in the news every week. The recent announcement of a newly formed Additive Manufacturing Center of Excellence is another sign of how the industry is growing up, realizing the need for “standards to create a common language and consistency in materials and processes, efficient testing, and applications use”. Bravo!

However, for this endeavor to truly be a success, the market’s dirty little post-processing secret must be addressed. This is, of course, the minimally-discussed reality of unfinished parts off the printer.

We continue to hear from customers who implement 3D printers into their operations without understanding the requirements for post-processing, even though we are now decades into the technology’s existence. And it’s not just that these parts need finishing in both the removal of support material and finishing of rough surfaces. It’s that tedious manual labor and old school traditional manufacturing techniques that have been used as the band-aid will never enable an additive manufacturing operation to scale. Neither produces high quality, consistent, repeatable end parts.

So as industry standards will use the control of digital data to qualify 3D printers and processes, why shouldn’t this standard also apply post-processing?

It absolutely should. And it’s absolutely possible with PostProcess’s software-driven solution because we have digitized the post-print step. Our hands-free, automated systems take the guesswork out of post-printing with algorithms developed from benchmarking thousands of parts. With AUTOMAT3D’s built-in finishing programs as well as the ability to create and store new programs, it’s as simple as pressing play to get the same end part every time.

As the article states, “by ensuring additive manufacturing steps are fixed and repeatable, customers can be more assured of part quality.” Amen.

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3D printing is all about digital, with software-driven systems at every step of the additive manufacturing process…until you get to the finishing step in post-printing. Software isn’t a focus in the traditional manufacturing finishing world today either. Traditional manufacturing finishing machines are typically either completely manual or utilize simple temperature control. In any case, they aren’t able to be worked into an automated process.

Connecting a process stream via software is key to optimizing efficiency in any process. Continuous improvement is dependent on being able to collect data, and logging data automatically drastically reduces the time it takes to analyze enough data to make an informed decision on process changes.

Many traditional manufacturing processes already utilize some type of product lifecycle management software. That same automation will be necessary for industrial 3D printing to scale. Additive manufacturing is already intelligent in the design and build phases… why stop at the post-print phase?

Here at PostProcess, we’re focused on unleashing the market’s potential by opening up the post-print bottleneck with our two software platforms, AUTOMAT3D™ and CONNECT3D™. AUTOMAT3D is our machine control – the brain of the operation. AUTOMAT3D is intended to design an optimal cycle for specific parts, based on part data received and historical data from internal lab testing. It controls all process variables based on selections made by the user such as cycle time, temperature, and agitation level.

What makes AUTOMAT3D special is the variance allowed, which is configurable by the user. It gives you the ability to cast a wide net or focus in on a specific type of part. And with that, our patent-pending hardware and chemistry technology are designed to finish all print technologies…so the possibilities are endless.

CONNECT3D is our software under development that will allow even further control of the process, which will be especially important in a production atmosphere. The idea is to connect the entire process, from design and build to post-printing. With the utilization of the upstream data available from the design file, it will work as a tool to increase the efficiency of AUTOMAT3D.

The success of the scaling of the 3D printing market is dependent on consistency and repeatability. Standards and Q/A come from consistency and repeatability. You can’t come up with standards if you get a different result every time. You can’t get consistency and repeatability with traditional finishing processes that rely on skilled operators.

You need intelligent machines that can be inserted into a process that utilizes manufacturing management software. Good thing we invented all that.

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As the pioneer of the automated 3D post-processing market, we’re regularly fielding questions as to how exactly a software-driven post-printing system works. It’s a mind shift for the industry to think about digitizing the tribal knowledge that they have developed in their print operations. But once they see the transformational benefits of software-driven automation with increased throughput, consistency, and productivity, the light bulb goes off.

So we put together this quick reference to the question “What is AUTOMAT3D™?”. And while software is the brains of the operation, it’s just one component of our comprehensive hardware, software, and chemistry solution. Learn more about our entire suite of post-printing solutions here.

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Every day there’s another article about the latest 3D print material or technology that fills our news feeds and inboxes. As the pioneer of the automated post-print market, we’re focused on transforming the 3D printing post-processing space at a rapid pace as well, eliminating the bottleneck to let loose exponential market growth.

In our pioneering journey, we’ve become experts at listening to customer feedback and evolving our solutions to align with the fast-growing market…not just in the scalability and versatility of our product line that addresses all 3D print technologies across a range of part sizes and print volumes, but also with the functional design of our systems.

So today we want you to meet the next generation PostProcess DEMI 800 and learn about the newest features born from real customer feedback, a constant source of our innovation. These are a just a few examples of the ways we’ve made the DEMI 800 easy to operate and maintain, so you can press the PLAY button and get back to printing more parts.

– Improved Footprint & Access: Reduced width by 20% for a better fit on crowded production floors. Open access on all sides of the machine with wide-swinging doors on 4 sides. The electrical enclosure includes a lift-off door and swings out over 90 degrees to allow access to both the electrical and plumbing components from the back of the machine.

– Improved Interface: Building on the success of the original model, we’ve added an overflow strainer to catch larger pieces of support material. The strainer has been redesigned to be smaller, lighter, and easier to lift in and out (see picture above). The redesigned tank top has lighter bi-fold lids and a drip-catching rim – any detergent that makes its way onto the top of the unit is prevented from dripping down the sides and instead runs back into the tank.

– Improved Operation: A new all-stainless filter with easy-to-use drain and shutoff valves, manifold cleanout ports, and main machine drain valves with a convenient garden hose adapter has been added. Plumbing that delivers detergent from the pump to the tank has been reconfigured to use fewer overall parts with a more streamlined design. An upgrade has been made to three cooling fans blowing on the tank bottom to more precisely regulate process temperature.

The DEMI 800’s hardware is just one part of our comprehensive solution. We also continue to innovate and improve our first-of-its-kind AUTOMAT3D™ software and chemistry formulations, specifically tailored to 3D print materials.

Learn more about our entire Support Removal family of systems here.

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For this week’s blog post, we’re featuring the launch of our latest White Paper that addresses support removal on one of the most commonly utilized 3D print technologies – Fused Deposition Modeling, or FDM.

This White Paper will discuss how throughput may be limited with traditional submersion support removal systems. We’ll review why current “default” mechanical and chemical post-print methods for FDM are inadequate along with details of the revolutionary Volumetric Velocity Dispersion (VVD) automation technology. See how VVD utilizes different forms of mechanical energy to increase FDM support removal efficiency, reduce drying time, and mitigate the risk of damaged parts.

Access the White Paper here.

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You and your team have worked hard on a new production-ready FDM design with intentions of avoiding the purchase of a costly mold. From feature strength and tolerances through functionality and aesthetics, everything looks great on your computer screen and expectations are high. Next, you run it through some default parameters within your slicing software, press print, and walk away, right? This critical step is often taken for granted. If you overlook design and file processing upstream, you may experience unexpected results or settle for poor quality that will not survive your required finishing process downstream.

In order to achieve that ‘injection-molded finish’, a sound part structure is essential. Here is an example of a part build that was not optimized, leading to warping and separation. By reorienting the build path, the gaps created by the default raster parameters were filled and strengthened. The part is now stronger and porosity was eliminated to take on the appropriate finishing needs.

Left: Raster gaps (before); Right: Gaps eliminated (after); Fix: Reorienting Build Path

In addition, critical geometries such as mating surfaces and load-bearing features may not achieve sufficient density or detail. Here you can see that a critical mating feature was essentially glossed-over in the printing process due to printer limitations in the initial build orientation. By rotating the build, you can build the appropriate contours and accurately print the desired feature.

Left: Poor print orientation, lack of detail (before); Right: Proper orientation, accurate detail (after); Fix: Adjusting Build Orientation

Another consideration is wall thickness. There will be instances where default parameters will leave your walls hollow. During support removal in traditional dunk tanks or baths, this space will allow solution and contaminants to get in between your build material, leading to a weakened or damaged part. During design, the interior wall can be thickened or the contours can be rotated to eliminate those gaps. Additionally, if you are subject to porous part builds, an automated PostProcess spray solution like the BASE or DECI that was used to finish the parts shown here will avoid the ‘soaking’ effect that can cause support material within hallowed walls to swell and cause damage.

This example FDM part (click for full screen) that was printed with the intention to be finished with injection-molded quality was achieved in two steps with a combination of PostProcess’ automated, intelligent solutions – 1) one minute of technician attendance time in the DECI Support Removal solution to finish a batch of 16 parts in 1 hour process time, and 2) five minutes of technician attendance time in the NITOR Surface Finish solution to finish a batch of 50 parts in 6 hours process time. The combination of PostProcess’ proprietary chemistry, highly engineered hardware, and AUTOMAT3D® software creates a complete solution that allows for just minutes of touch time instead of what would have previously required many hours of manual technician labor.

By including the above design practices into your process, you will set your part up properly for the required finish. Without these design considerations, you will find yourself hard-pressed to achieve that ‘injection-molded’ finish you are striving for. And when you are ready, contact PostProcess for a complete automated finishing solution to take your additive manufacturing workflow to full production.

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