Since its launch in November 2021, the SFM-AT350 depowdering system has developed into a top seller for medium-sized parts. With key upgrades, Solukon has made the best-selling depowdering system in the mid-range segment even smarter and more transparent – and it now cleans even more efficiently. All upgrades will be exhibited at Formnext 2023.

The SFM-AT350 is the depowdering system for medium-sized parts up to a height of 420 mm and a weight of 60 kg. High freedom of motion, a compact structure with optimized chamber volumes and along with it, a minimal inertization time, are the main features of the system. Solukon customers worldwide appreciate the unique features of the mid-range machine. Immediately after its launch, the SFM-AT350 established itself in the additive manufacturing market and is the top-selling system in its class. At the same time, similarly to metal parts in the large part segment, a trend toward increasingly complex parts is detectable. To continue to be ready for all geometries, however challenging, Solukon continuously develops and refines its systems. With three key upgrades, Solukon has now made the SFM-AT350 even stronger.

SPR-Pathfinder® depowdering software for the SFM-AT350

It is no longer necessary to program complex cleaning sequences for the SFM-AT350. Instead, they can be calculated quickly and easily with the worldwide unique SPR-Pathfinder® software. Around a year ago, Solukon launched the SPR-Pathfinder® – initially for the larger SFM-AT800-S and SFM-AT1000-S systems. Now it is available for the mid-range segment. Based on the CAD file of the build job, the SPR-Pathfinder® calculates the ideal motion sequence in the Solukon system for removing excess powder from complex interior structures. The calculations of the software are based on a flow simulation that analyzes the part’s digital twin. The individually calculated motion sequence is then read by the Solukon system, which in turn runs the programmed paths. This ensures that even the most complex parts with labyrinth-like channels are cleaned – not to mention in record time and without any human programming effort. “Smart, software-supported depowdering is also the key to serial cleaning with the SFM-AT350 and therefore, real serial production,” said Andreas Hartmann, the CEO/CTO at Solukon.

SFM-AT350-E: New form of excitation for delicate structures

The SFM-AT350 was not only upgraded on the software side: the form of excitation was also upgraded. In the future, Solukon will offer the depowdering system as the
SFM-AT350-E with piezoelectric excitation. Users will have the choice between two completely different excitation forms: the familiar pneumatic form in conjunction with a vibrator and an optional knocker, and piezoelectric excitation.

Since piezoelectric excitation originates directly at the rotary table of the Solukon system, the part can be shifted to the optimal vibration range with high precision. The high frequencies of the electronic excitation are considerably higher than the harmful natural frequency of the part. As the frequency constantly controls and regulates itself the risk of exciting the resonance frequency and damaging sensitive structures is avoided. Consequently, the SFM-AT350-E is the ideal depowdering system for delicate structures made from materials that are difficult to depowder, like copper. Another major advantage of the new form of excitation is its low levels of noise emission. As a result, the SFM-AT350-E is a perfect fit for the naturally quiet 3D printer environment.

“The requirements for depowdering increase as part complexity, material complexity and diversity increase. Growing production quantities are also an influential factor. At the same time, our customers want us to provide systems that are very easy to operate. After experiencing a breakthrough with the launch of our smart SPR-Pathfinder® software, which calculates optimal part motion, we have achieved a further milestone upon launching the SFM-AT350-E: For any depowdering challenge, we can now offer the optimal frequency excitation,” said Andreas Hartmann in summary of the importance of the new machine variant.

To determine whether the SFM-AT350 with pneumatic excitation, a vibrator and a knocker, if required, or the new SFM-AT350-E with piezoelectric excitation is the right machine, Solukon consults closely with interested parties and customers on a case-by-case basis. The following table may provide helpful information.

The advantages of the variants at a glance

SFM-AT350 with pneumatic excitation	SFM-AT350-E with piezoelectric excitation
reliable cleaning of complex structures	reliable cleaning of complex, delicate structures
optional knocker system for dissolving powder clumps	particularly gentle cleaning through very high and self-regulating vibration
most inexpensive SFM-AT350 variant	low-noise
compatible with SPR-Pathfinder®	compatible with SPR-Pathfinder®

Both the piezoelectric excitation form (the SFM-AT350-E) and the SPR-Pathfinder® are available as options for the SFM-AT350 effective. Users have the opportunity to see the performance of the SPR-Pathfinder® for themselves as part of a 30-day test version.

New tracking options with enhanced Digital-Factory-Tool

Just like the SFM-AT800-S and SFM-AT1000-S, the SFM-AT350 and SFM-AT350-E are both available with an enhanced Digital-Factory-Tool (DFT). This enhanced DFT includes several new key features that will be introduced soon in a separate press release.

Launch of the SFM-AT350-E with SPR-Pathfinder® and enhanced DFT at Formnext 2023

Solukon is launching the SFM-AT350-E with SPR-Pathfinder® at Formnext 2023. From November 7–10, 2023 at booth 12.0, D42, Solukon is showing how the SPR-Pathfinder® software depowders the most complex geometries in an SFM-AT350. Solukon is also exhibiting the new SFM-PCU powder collection unit with an SFM-AT1000-S.

Cooperation between Reichenbacher and Solukon combines essential postprocessing steps and enables the first automated box unpacking.

The removal of unfused powder is a central step in the postprocessing of metal parts made using additive manufacturing. For years, market-leader Solukon’s systems have removed powder automatically from parts manufactured with LPBF processes. A project with Reichenbacher Hamuel GmbH is now taking it a step further and automating both unpacking from the container and depowdering in a single system.

After the LPBF process, the printed part is in a kind of “powder cake” of unused metal powder in a container. Unpacking the part, i.e., freeing the part from the powder cake, generally involves vacuuming and clearing away powder. Once the part is uncovered and removed from the container, it is placed in a Solukon system in order to automatically remove any unfused metal powder from the interior of the complex part. Using programmable two-axis rotation and vibration, the powder becomes fluid and can flow out of the interior channels in a controlled manner. This is how the powder is usually removed from complex laser-melted metal parts. The Reichenbacher – Solukon project steps in here, combining the two process steps in an automated system for the first time.

The operating principle of the combined unpacking and depowdering station

It is essential to the Reichenbacher – Solukon project that not the part alone, but rather the entire container in which the part sits is loaded into the SFM-AT1000-S. The Reichenbacher box, which has a removable bottom and sides, is secured via a zero point clamping system, then rotated upside-down, and the first of the loose powder from the powder cake is emptied automatically. Discharged powder is fed directly into an external material preparation station.

Then, the user removes the box frame with an external mobile lifting device or crane, so that the part is fully accessible. The Solukon system (short swivel arm version) then cleans the part as usual using one-of-a-kind SPR technology® with programmable two-axis rotation and adjustable vibration. With the SPR-Pathfinder® software, the motion sequence in the Solukon system can be calculated in advance easily and automatically using the part’s CAD file. The SFM-AT1000-S can accommodate boxes up to 800 kg and, with the help of a high-frequency knocker, can loosen even stubborn powder clumps in the part’s interior channels.

“The SFM-AT1000-S with box unpacking is a project with a high degree of automation. Furthermore, it demonstrates how flexibly our systems can be used for individual customer solutions. We are happy to support Reichenbacher in their project unpacking boxes of laser-melted metal parts. This is how, together, we create a real competitive edge for Reichenbacher’s customers,” says Andreas Hartmann, CEO and CTO of Solukon. Together with Reichenbacher’s Additive Manufacturing Team, led by Dr. Alexander Kawalla-Nam, this has led to an industry-ready automation solution in record time. “With Solukon, we once again have a system in our portfolio that has a truly unique selling point and makes us stand out in the area of postprocessing against standard solutions on the AM market. This puts Reichenbacher in a position to map the entire 3D printing process chain. We thank Mr. Hartman and team for their openness and fast execution of the project,” Dr. Kawalla-Nam adds.

The SFM-AT1000-S for combined unpacking and depowdering is now available from Reichenbacher. Solukon is participating as system vendor.

Industrial customer already using combined system

The SFM-AT1000-S has already successfully passed its box unpacking field test. A leading manufacturer of steel molds for the concrete industry has already been using the system for months.

Additional information and details on the operating principle of the new system will follow shortly in an extensive user report.

About the project partners

Reichenbacher Hamuel GmbH is a subsidiary of the SCHERDEL Group and has made a name for themselves globally as a first-class manufacturer of CNC processing centers thanks to their impressive capacity for innovation. At their Dörfles-Esbach location near Coburg, they are developing and manufacturing five-axis systems that live up to the highest safety standards and can also be deployed in the construction of airplanes, automobiles, ships, and rail vehicles, as well as in the woodworking industry, or in the manufacture of aluminum, plastic, or composite parts. Since 2020, Reichenbacher has specialized in large-format and industrial 3D printing systems that encompass the entire process chain in a single system. Specifically, their focus is on the industrialization of the L-PBF (Laser Powder Bed Fusion) process as well as hybridized manufacturing (material extrusion with post-treatment milling). With this, Reichenbacher is breaking the mold in both industrial applications and the AM market with their individualized, customer-oriented solutions.

Solukon Maschinenbau GmbH is a German high-quality supplier of powder removal and processing systems for metal and polymer additive manufacturing. Founded in 2015 by Andreas Hartmann and Dominik Schmid, the company, located in Augsburg, has extensive experience in the development of AM systems and related peripheral equipment, and offers a full range of industrial powder processing systems. Since 2022 Solukon offers an intelligent software for automated depowdering of laser-melted metal parts as exclusive licensee, the SPR-Pathfinder®. Solukon products meet the highest functionality and safety standards and are approved for safe and reliable removal of tough-to-handle and reactive materials such as titanium and aluminum. Solukon has established as a market leader in the field of industrial powder removal with its metal depowdering systems.

Solukon has equipped the SFM-AT1000-S with an optimized swivel arm for parts manufactured with the NXG XII 600 from SLM Solutions. An optional front-top-loading feature makes it easier to handle parts. Solukon will launch the special version of the SFM-AT1000-S at this year’s Rapid + TCT in Chicago.

Everyone’s talking about the NXG XII 600 from SLM Solutions, which has set the standard for the serial production of metal laser-melted parts. The machine is used to manufacture particularly large and heavy metal parts, which places high demands on industrial depowdering in turn. The SFM-AT1000-S from Solukon has been the depowdering system for such large and heavy parts since its launch in 2020. With a reinforced body and higher torque than the smaller SFM-AT800-S, it can safely and easily depowder parts weighing up to 800 kg. In close collaboration with SLM Solutions, Solukon has optimized the SFM-AT1000-S depowdering system with specific features for the NXG XII 600.

Short swivel arm for optimal center of gravity balance position

Taking into consideration the build plate, NXG XII 600 parts can reach sizes of 600 x 600 x 660 mm. This locates the center of gravity closer to the rotational axis of the swivel arm when they are placed in the Solukon SFM-AT1000-S. To reach an optimal center of gravity balance position, Solukon now offers a version of the SFM-AT1000-S with a short swivel arm. The short swivel arm also makes the part easier to access if users want to finish depowdering manually via the sealed glove ports.

New option: Front-top-loading for easier parts handling

It’s now even easier to load the SFM-AT1000-S, thanks to the pneumatic top. When the top opens, it folds up together with the upper door frame, such that the part can be inserted at turntable height with even more flexibility – it’s no longer necessary to ”thread in” the part from above. This enables particularly large and heavy parts to be lifted easily and conveniently into the system via crane by using lifting tools provided by SLM Solutions. Additionally, the front door can be opened wider than before, which makes loading and unloading bulky parts easier.

Both the front-top-loading and short swivel arm are currently available as options for the SFM-AT1000-S.

SFM-AT1000-S: Version comparison

The new option with a short swivel arm extends the compatibility of the SFM-AT1000-S depowdering system from Solukon. The table presents a comparison of both versions:

	Short swivel arm	Long swivel arm
Part dimensions (X x Y x Z incl. build plate)	600 x 600 x 660 mm	600 x 600 x 1,000 mm
max. Part weight	800 kg	800 kg
Front-loading	Standard	Standard
Front-top-loading	Optional	Optional
Advantages	-Depowdering of compact parts with special center of gravity position -Improved part accessibility	-Depowdering of particularly large parts

The video illustrates the new loading option for the two SFM-AT1000-S versions.

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Solukon will launch the new version of the SFM-AT1000-S with front-top-loading and short arm at Rapid + TCT in Chicago, Illinois (May 2-4, 2023). The Solukon team looks forward to welcoming you at booth 1820.

Die SFM-AT1000-S: the leading depowdering system in the large-part sector

Like all Solukon systems, the SFM-AT1000-S is also based on the unique SPR® Smart Powder Recuperation Technology. Thanks to automated, programmable rotation around two axes and adjustable vibration, the Solukon systems remove all powder residues in a part’s internal channels in a reliable and fully automated process. The controlled flow of powder out of the most intricate channels and windings becomes more difficult when using materials like copper or aluminum, since these materials often get clogged inside internal channels. A new knocker was designed to address this problem. With finely adjustable mechanical knocks, clogged powder is loosened and can flow out in a controlled manner.

Digital features make the SFM-AT1000-S the most intelligent and best depowdering system on the large-parts market:

The Digital-Factory-Tool monitors the process and records all important data, including humidity, vibration, and gas consumption, and displays these values in a detailed quality report. The entire process is transparent and provides the data for qualification and certification in demanding serial production. With OPC UA, Solukon provides the interface for easy automation integration.

SPR-Pathfinder® software uses the CAD file of the complete build job to calculate the ideal motion sequence for removing powder from complex internal structures as quickly as possible. The software calculates the best possible motion sequence in conjunction with fluid simulation and an intelligent algorithm. Complex programming tasks that exceed spatial imagination are thus safely and conveniently automated.

SLM Solutions also acquires a new-generation SFM-AT1000-S

Both SLM Solution’s customers and the OEM from Lübeck trust Solukon’s expertise. After purchasing an SFM-AT800-S in 2021, SLM Solutions has an SFM-AT1000-S with front-top-loading and short arm in its facility and uses it to reliably and quickly depowder NXG XII 600 parts.

Long-standing partnership between SLM Solutions and Solukon

With the development and purchase of the new Solukon SFM-AT1000-S specifically equipped for the NXG XII 600, Solukon and SLM Solutions have strengthened their long-standing partnership. “The NXG XII 600 is the gold standard in industrial 3D printing. We are also collaborating with the market leader in the area of depowdering, and are glad that Solukon is launching a depowdering solution that fits our system perfectly,” says Sebastian Feist, Product Manager for Factory Integration & Periphery from SLM Solutions.

Andreas Hartmann, Solukon’s CEO/CTO, is certain that his company is equipped to meet the trend of increasingly large parts: “The NXG XII 600 from SLM Solutions has set the entire large printer market in motion. We are happy that we can now offer the numerous NXG XII 600 users a customized depowdering system as well. Even larger parts measuring 1,500 millimeters, produced on an NXG XII 600E for example, or more on the Z-axis will inevitably require Solukon automated depowdering solutions. We are in ongoing discussion with manufacturers to ensure that we can always provide the right system. The SFM-AT1000-S for NXG XII 600 will not be the last Solukon system for the large-format printers.”