This provocative statement comes from the cover story of the latest issue of ADDITIVE FERTIGUNG magazine. Find out in this article why we at Solukon see industrial depowdering as an important part of the manufacturing process instead.

Einleitung

Almost ten years ago, Andreas Hartmann and Dominik Schmid founded Solukon Maschinenbau GmbH. The company from Augsburg, Germany, is now the go-to for depowdering LPBF metal parts. With pioneering innovations, the depowdering specialists have successfully raised the bar for unpacking complex geometries again and again

The story of Solukon began in 2012, when Andreas Hartmann and Dominik Schmid founded their own engineering office for special-purpose machines. However, the real success story started in 2013, when a customer from the automotive sector inquired about a depowdering solution for LPBF parts. One year later, the partners shipped the first system. “Since we both came from the voxeljet AG environment and therefore had experience in handling powder materials, the inquiry struck a familiar chord and in a relatively short time, we were able to provide a solution that met the customer’s requirements,” recalled  Hartmann. The main requirements for the first system focused on safety in general and occupational safety in particular. “In powder-based AM metal production, we frequently dealt with reactive materials with particle sizes that could penetrate the lungs. This is why it was obvious early on that a closed system would be necessary for depowdering these types of parts. It would have to enable inerting, and contact-free powder handling as well,” said the CEO.  

Wide range of requirements

It quickly became clear that depowdering metal parts made with additive manufacturing involved several additional challenges. Metal AM parts often have complex inner geometries like channels and conduits, narrow cavities and tight support structures. Significant amounts of powder can remain in all of these geometries. Inadequate depowdering can lead to clogged channels, which in turn have a negative effect on the function of the part. And the residual powder in support geometries is lost when the part is sawed off the build platform. “All of these challenges show that depowdering is a key process step in additive metal part manufacturing with powder materials. We no longer classify depowdering as postprocessing—as a downstream process step—but instead as a decisive part of the manufacturing process,” Hartmann explained in detail. There was clearly sufficient demand for suitable depowdering machines for AM parts, which led to the founding of Solukon Maschinenbau in 2015. That same year, the company shipped the first SFM-AT800 – in the beginning, an automated system with programmable 2-axis rotation, vibration and inerting with protective gas.

Cleaning with vibration excitation

Powder materials in additive manufacturing must have a specific degree of flowability to ensure that the manufacturing processes are smooth and reliable. During the manufacturing processes, however, the powder layers are frequently compressed to the point that the resulting powder cake has trouble trickling away, which makes depowdering much more difficult. “We had to deal with this problem at voxeljet back in the day and were therefore aware that we had to find a way to improve the flowing properties of the power. There are basically two workable solutions: One method involves knocking the build platform with the workpiece on it, while the other involves applying vibrations to the system, which makes the powder act like a liquid. Depending on the material, knocking or vibration—or a combination of the two—leads to the best results,” said Hartmann. “For delicate structures, piezoelectric excitation at ultrasonic frequency replaces pneumatic excitation.”

Launch of SPR-Pathfinder software as milestone

In 2019, a collaboration with Siemens and, in particular, their idea generator Christoph Kiener led to the development of the SPR-Pathfinder software solution. Using the CAD file of the build job, the software detects the inner channels and, in advance, calculates the optimal motion of the swivel system of the Solukon machines for
the cleaning operation. When it comes to cleaning time and cleanliness, this is particularly interesting for parts with multiple twisted channels, like the cooling channels in injection molds. As early as the design phase, software users can check whether or not the geometries they designed can be completely depowdered and adjust the design if necessary. This way, parts that would probably deliver unsatisfactory depowdering results are not printed at all. “This development was another milestone on the way to establishing our depowdering solutions in the market. Safety-critical sectors like the medical industry and the aerospace industry have the highest standards of cleanliness and freedom from powder for their parts. With our technology, we can offer exactly that, which makes us the world’s first choice when it comes to depowdering metal parts. After the joint development phase with Siemens, we took over SPR-Pathfinder in 2022 and turned it into a commercial product. Since then, we have continuously developed it further,” explained Hartmann. He added: “For us, it has always been important to align our developments to the needs of the market.This also means that we tend to implement a moderate approach when it comes to company growth. We have managed to do well without third-party funding, which is something we are very proud of.

Analyzing and understanding key industries

The key features of Solukon machines are outstanding workmanship and high technical maturity. To become established in markets like the aerospace industry and medical technology sector, the highest standards must be met. “These sectors in particular demand consistently high quality that is reproducible. To deliver this, it is important to understand the criteria that determine quality and transfer them to an automated process. We have combined the two steps in our SPR® Smart Powder Recuperation technology. Alongside consistent, automated, path-guided depowdering with adjustable vibration, this also involves recovering as much residual powder as possible. Powder materials are a valuable raw material, and they must be recycled to the greatest possible extent,” said the CEO to summarize the market requirements.

Increasingly large LPBF systems whose build platforms must be depowdered are being launched, and Solukon reflects this in its constantly growing machine diversity. SFM-AT1500-S is the latest flagship of the portfolio. This depowdering system was specifically developed for cleaning extra-high, heavy and complex parts such as rocket engines. The system can accommodate parts up to 1,500 mm high with weights of up to 2,100 kg. Alongside the comprehensive range of machines for depowdering metal parts, Solukon offers the SFP series with depowdering solutions for polymers.

Success with growth potential

Andreas Hartmann summarizes the success of Solukon like this: “We started out as an engineering office with the goal of offering industrial solutions for a variety of sectors. Ten years ago, we identified a niche that lacked practical solutions and developed our depowdering solutions. Our customers benefit from our grasp of technology and first-class engineering work when it comes to implementing our systems. Reliability, high quality standards and innovative power are at the top of our list—and our international customers also appreciate these qualities. We offer our customers more than the highest level of machine quality and reliable cleaning results: providing customer-specific consultation with our experts is our other distinguishing feature. Material-specific forms of excitation, clamping systems, handling support structures, setting software parameters, etc. are all topics that our competent teams of experts have answers for. In depowdering tests with real parts, interested parties can also see the quality of the cleaning process for themselves in advance and without obligation. We are optimistic about our continued success in the next ten years and look forward to accepting new challenges from the market.”

Artikel jetzt im E-Paper des Magazins ADDITIVE FERTIGUNG lesen

This article is the cover story of the magazine ADDITIVE FERTIGUNG. Access the e-paper here (Geman version only).

The Solukon team is happy to reconnect with the US AM community again – this year in Detroit, MI. Here’s what to expect at booth 2127.

SFM-AT1500-S – The new Titan for Automated Depowdering

This highly advanced depowdering system is specifically designed for cleaning extra-large, heavy and complex parts, such as rocket engines. With an impressive capacity to accommodate components up to 1500 mm in height and weights of up to 2100 kg, the SFM-AT1500-S sets a new benchmark in automated cleaning. Explore the new dimensions of depowdering at Rapid + TCT with a big machine demonstrator setup.

Ultrasonic Depowdering System SFM-AT350-E

The SFM-AT350-E is a depowdering system equipped with ultrasonics. It offers an additional option to the traditional tools of depowdering pioneered by Solukon: vibration, knocking and rotation. Ultrasonic excitation works in an ultra-high frequency range and is electronically controlled for highly efficient part cleaning. It is generally used for more delicate parts with fine structures or internal channels. Discuss with our experts at Rapid + TCT when ultrasonic excitation is the way to go for your depowdering challenges.

Just like the standard depowdering system SFM-AT350, the E-version can accommodate parts weighing up to 100 kg as well as plates of the flagship printers EOS M 400 and Nikon SLM® 500.

Do not miss the world premiere of the new SFM-AT1500-S at booth 12.0, D71.

It’s that time of year again! Formnext, the leading conference for additive manufacturing, will be held from November 19-22, 2024 in Frankfurt am Main. Solukon is excited to welcome customers and partners to Hall 12.0, Booth D71 – live and in person!

World Premiere: SFM-AT1500-S – A New Era of Automated Depowdering

Just in time for Formnext 2024, Solukon unveils its latest advancement in depowdering technology: the SFM-AT1500-S. This highly advanced depowdering system is specifically designed for cleaning extra-large, heavy, and complex parts, such as rocket engines. With an impressive capacity to accommodate components up to 1500 mm in height and weights of up to 2100 kg, the SFM-AT1500-S sets a new benchmark in automated cleaning.

What else is on Display?

In addition to the SFM-AT1500-S, Solukon will showcase another proven depowdering system, including the SFM-AT350-E. Thanks to a redesigned arm, this model can now handle parts weighing up to 100 kg as well as plates from the flagship printers EOS M 400 and Nikon SLM® 500.

Visit us to experience the latest advancements in automated depowedering. We look forward to welcoming you at our booth and introducing you to the possibilities of our innovative systems.

Solukon dedicates a webinar to this crucial topic in collaboration with airdusco, an independent engineering company that specializes in combustible dust consultation, dust collection and explosion protection systems design.

Tacking Safety Challenges in Powder-Based AM

As powder-based additive manufacturing (AM) technologies continue to expand, so do the challenges surrounding the safe handling, processing, and depowdering of combustible and explosive dusts and powders. To address these critical concerns, an upcoming webinar will focus on the risks associated with AM and the solutions available to mitigate them.

This free online event, titled “Addressing Fire and Explosion Risks in Depowdering and AM”, will take place on November 7th at 2 PM EDT / 11 AM PDT via Zoom.

The webinar, presented in collaboration with Jason Reason from Airdusco, a highly experienced expert in the field, will offer valuable insights into fire and explosion hazards specific to AM environments. Topics will include understanding the risks, exploring depowdering safety solutions, and ensuring compliance with industry standards.

Whether you’re seeking to improve safety measures or deepen your understanding of potential risks, this webinar is a must-attend.

Secure your spot today by registering for this informative session.

The Solukon team is happy to reconnect with the East Coast US AM community again. Here’s what to expect at booth 433126.

For the first time in his nearly decade-long history Solukon will exhibit at IMTS, the largest manufacturing technology trade show in North America.

Save the date

September 9-14
McCormick Place Chicago | Illinois
Booth #433126 (West Building Level 3)

Discuss Depowdering with Our Experts

Discuss with our experts Michael Sattler (Global Sales Director) and Alexander Wintermeier (Project Manager) how our market-leading depowdering technology boosts your additive manufacturing production line.

Meet Team MAHAR

Our Certified Solukon Partner MAHAR will co-exhibit. The Team around Michael Kowaleski is happy to meet you!

See you soon at IMTS in Chicago!

The Solukon team is happy to reconnect with the US AM community again – this year in Los Angeles, California. Here’s what to expect at booth 2161.

Enhanced Depowdering System SFM-AT350

Thanks to its adapted arm design, the SFM-AT350/-E can now accommodate parts weighing up to 100 kg as well as plates of the flagship printers EOS M 400 and Nikon SLM® 500. Also, you’ll have the chance to view the E-version of the SFM-AT350: The first and only depowdering system with ultrasonic excitation for the cleaning of sensitive structures.

What else is at display?

Beside the SFM-AT350/-E you’ll have the chance to see the SFM-AT1000-S live and in color. It’s maximum capacity of 800 kg and the flexible front-top loading makes it THE depowdering system for aerospace.

SPR-Pathfinder®-Software Discount Campaign

The newest version of our unique depowdering software SPR-Pathfinder® introduces several thrilling enhancements like a pre-simulation of the powder removal process or an optional pre-cleaning.

The new software version marks a milestone for us we want to celebrate with you. As a token of appreciation for your continued support, we’re offering an exclusive discount campaign for our cutting-edge SPR-Pathfinder® Software.

Learn more via a separate mailing or directly at our booth 2161.

See you soon in Los Angeles, California, Home of a range of space companies and our Mission Patches!

In recent years, industrial depowdering has become an integral component of the process chain of the laser melting process. Solukon is a pioneer and market leader in automated depowdering.

CEO/CTO Andreas Hartmann talks about the current trends in powder removal and shows how even traditional manufacturing segments like injection molding can benefit from Solukon technology.

Andreas, what trends do you see in industrial depowdering?

First of all, the industrial sector has developed from “why” to “how.” In other words, our customers and other interested parties have recognized that for high-quality additive manufacturing, they inevitably need automated powder removal. They are closely examining the individual benefits and specific applications of our technology now, instead of asking why they even need depowdering. We have been a primary driver of this important development and the entire sector will benefit from it.

A second important trend is the increasing digital integration of automated depowdering.

Why is digital integration of depowdering important and how is it done?

The processes downstream from printing must flow transparently in order to give users an undistorted picture of the efficiency of their additive production lines. We supply two key tools for digital integration: first, the Digital-Factory-Tool (DFT), a sensor and interface kit for process monitoring, automation and digital integration. Via OPC UA, all data and facts on the depowdering process can be integrated into the higher-level digital dashboard of the printer. The new aspect is that the DFT uses media consumption data to output the carbon footprint of the depowdering process as well. With this feature, we have anticipated future standards and regulations.

The second digital tool is SPR-Pathfinder®, our unique depowdering software that makes all programming effort unnecessary. Users simply load the CAD file of the build job into the software, which automatically calculates the optimal movement. With this software, complexities like internal channels no longer play a limiting role. A new feature: our SFM-AT350 for medium-sized parts is now compatible with SPR-Pathfinder®. A wide range of customers from all segments of industry benefit from this.

Which industrial segments rely on automated depowdering systems nowadays?

Of course I want to start out with the most classic field of application: aerospace, where the parts being manufactured are so complex that automated depowdering is a necessity. After all, it is impossible to ensure that a heat exchanger is powder-free and ready to go into space just by knocking and brushing. Next, of course, the automotive industry, energy and printer manufacturers themselves, such as EOS, Velo3D and SLM Solutions. These segments cover the majority of the approximately 250 systems we have in the field.

In recent months, we have also noticed a strong increase in other segments. Medical technology is one example. The depowdering challenge is a bit different there. Instead of complicated, convoluted cooling channels, we see a lot of porous lattice structures on the surface of medical parts. The powder often sticks there and has to be removed systematically and gently. In response, we are launching a special version at Formnext 2023: the SFM-AT350-E with piezoelectric excitation. In it, the excitation originates directly at the rotary table of the Solukon system, putting the part in the optimal vibration range with high precision. The ultrasonic frequency of the electronic excitation is considerably higher than the harmful natural frequency of the part. This way, the risk of exciting the resonance frequency and damaging sensitive structures is avoided. At the same time, the process is virtually noiseless.

Alongside medical technology, we have recently acquired customers in the tool making and injection molding sectors.

Those are sectors that people initially associate with conventional manufacturing, right?

Yes, sure, but many companies in those sectors are very open to new technologies. Paul Horn, the carbide toolmaker, for example, also relies on additive manufacturing for producing tool parts. They successfully depowder their tools with a Solukon system. Another interesting use case is our customer Witosa, a renowned manufacturer of hot runner systems for injection molding. They implemented the world’s first additively manufactured one-piece hot runner nozzle, which catapulted them to the top of the segment in the global market. Witosa cleans its MONOLITH® nozzles, as well as other products, in an SFM-AT350 from Solukon. With our SPR® depowdering technology, we ensure that these parts are thoroughly cleaned and no residual powder that could negatively affect the postprocessing or even the quality remains.

We have now spoken about many different fields of application. What do all Solukon use cases have in common?

To all our customers, it is important to clean reliably and repeatably. In other words, the same process and same result for structurally identical parts. This sounds fairly banal at first, but reproducibility is exactly what makes serial cleaning – and with it, real serial production – possible.

The Solukon team is happy to reconnect with the AM community again. Here’s what to expect on booth 12.0, D42.

Solukon has a range of new products and features ready for the show of the year.

Automated Powder Collection Unit SFM-PCU

The Solukon SFM-PCU is an automated powder conveying station for all common metal powders. With a container of more than 100 liters, the SFM-PCU is the ideal peripheral system for large powder volumes.

SFM-AT350-E with piezoelectric excitation for delicate structures

Since piezoelectric excitation originates directly at the rotary table of the SFM-AT350-E, 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.

Also new: Both the SFM-AT350 the SFM-AT350-E are now compatible with SPR-Pathfinder® software.

Enhanced Digital Factory-Tool with carbon footprint tracking

The main upgrade in the enhanced Digital-Factory-Tool (DFT): the carbon footprint of depowdering is now measurable. From their energy supplier, Solukon customers find out the value for the CO₂  consumption per kilowatt hour of electricity. There is a variable input field in the upgraded Digital-Factory-Tool for this carbon factor of electricity, as well as the carbon factor of compressed air consumption. With the two values, the DFT calculates the carbon footprint of the depowdering process.

Our depowdering systems at display

We’re happy to have the following postprocessing systems on display.

• The new SFM-AT350–E with piezoelectric excitation and SPR-Pathfinder® software
• Die SFM-AT800-S with robot integration on neighbouring booth E41 of Rivelin Robotics
• Die SFM-AT1000-S with short swivel arm
• The new SFM-PCU für automated powder handling

The US AM market is one of Solukon’s core business areas alongside with Central Europe. To further strengthen its position in the US market and to offer Solukon’s US customers a local contact, Solukon cooperates with five trusted distribution partners from the United States.

Since the introduction of the SPR® (Smart Powder Recuperation) depowdering technology in 2015, Solukon is the known pioneer and market leader in industrial depowdering in additive manufacturing. To strengthen its market position, Solukon has already concluded distribution partnerships in Europe (e.g. Benelux, UK), Asia-Pacific (e.g. Korea, Australia) and Canada in the past one and a half years. Now, strategic partnerships with five U.S. companies follow, dividing the sales aera by state.

West Coast: DMARK Corporation

In the western USA, Solukon is now represented by DMARK Corporation. The company, based in Los Alamitos, California, now serves Solukon customers and prospects in the states of Washington, Oregon, California, Nevada and Arizona. Since 1987, DMARK has been providing manufacturers with the finest in CNC Machine Tools and Additive Manufacturing Equipment. DMARK’s team represented by VP & General Manager Robert Serrano are dedicated to helping their customers realize maximum productivity from their equipment investments.

Central US States: Hartwig Inc.

For the states in the middle of the US Solukon partners with Hartwig, Inc.. The contractual area of Hartwig covers the entire geographic area of the states Idaho, Utah, Montana, Wyoming, Colorado, New Mexico, North Dakota, South Dakota, Nebraska, Kansas, Oklahoma, Texas, Minnesota, Iowa, Missouri, Louisiana and Illinois.

Hartwig, Inc. is the Midwest’s largest machine tool distributor based out of St. Louis, Missouri committed to helping manufacturers control their destiny every day. Since the company’s founding in 1960 the Hartwig team has installed over 12,000 machine tools for its customers. Hartwig is known for their manufacturing solutions and support of turning, milling, grinding, EDM, and Additive Manufacturing. In the field of AM, Hartwig already partners with EOS with whom Solukon also has a strong partnership. The Solukon activities at Hartwig will be coordinated by Jens Kautzor, Additive Manufacturing Sales Engineer at Hartwig.

States around Lake Michigan plus Ohio, Kentucky und Mississippi: MAHAR

The distribution area of MAHAR Tool Supply Company, Inc. includes the states Wisconsin, Michigan, Indiana, Ohio, Kentucky and Mississippi. Since 1947 MAHAR has been a full-service tooling support partner, providing solutions for their customers from industries like automotive, medical or energy. MAHAR’s programs range from basic traditional supply to full commodity management programs. President Michael Kovaleski is responsible for the consulting of Solukon prospects and customers in the MAHAR region. In addition to the US states mentioned above MAHAR will also be the trusted Solukon agent for Mexico, Costa Rica and Puerto Rico.

North- and South-East: Phillips Corporation

The North- and South-East of the US will be covered by additive and machining expert Phillips Corporation. The company distributes Solukon machines in the states Maine, New Hampshire, Vermont, New York, Massachusetts, Connecticut, Pennsylvania, New Jersey, Delaware, Maryland, West Virginia, Virginia, Tennessee, North Carolina, South Carolina, Alabama, Georgia and Florida. Phillips, represented by EOS Product Manager Tim Grein, supports the future of manufacturing by providing unparalleled service, expertise, and innovative thinking for both subtractive and additive manufacturing processes. In AM Philips already features machines from EOS, among others.

Governmental Agencies in the US: BahFed

Nationwide, Solukon partners with Portland-based company BahFed Corp to supply federal, state and local government customers with Solukon depowdering stations. BahFed holds several GSA Schedules and is a NASA SEWP V contract holder, allowing the company to serve government agencies and organizations throughout the United States.

All US Solukon distribution partners will report to Michael Sattler, Global Sales Director at Solukon who is also responsible for the global reseller network. “As pioneer and market leader in depowdering it is important to us, that customers and prospect receive the best possible consulting service wherever they are located in the world. Partnering with DMARK, Hartwig, MAHAR, Phillips and BahFed will not only eliminate the time shift effects but gives every US prospect a regional depowdering contact person nearby”, says Michael Sattler.

Solukon distribution partners starting in May 2023

The Certified Solukon US Distribution Partners start their consulting and sales activities in Mai 2023. In addition to their service, the companies may also represent Solukon at trade fairs in their sales region. However, Rapid + TCT like Formnext will remain a Solukon exclusive event since it is the most important trade show in the US for the German depowdering expert.

Augsburg/Rupperswil – The depowdering pioneer Solukon is now cooperating with the Swiss company URMA AG in the Swiss AM market. By cooperating with URMA, Solukon is further expanding their already expansive global sales network and is banking on a true industrial heavyweight in Switzerland.

URMA designs and manufactures precision tool systems that are used globally in drilling precise holes. For more than 60 years, the family-owned company, which has approximately 130 employees, has been active globally in a wide range of subsidiaries, OEM partnerships, and a wide sales network. In addition to tool manufacturing, URMA AG has entered the additive manufacturing sector in recent years.

A holistic approach to the AM process chain

URMA AG takes an integrative approach when advising their clients in the field of additive manufacturing, distributing high-quality equipment from their notable and industry-leading European partners through all stages of the process chain, from preprocessing and manufacturing through postprocessing. The partners include Solukon and EOS, among others.

Solukon as the exclusive partner for industrial depowdering

URMA addresses the topic area of automated depowdering of metal parts exclusively with Solukon. Since 2015, Solukon has been a pioneer and market leader for automated depowdering in additive manufacturing. Solukon systems remove powder residue from complex metal parts entirely automatically through programmable 2-axis rotation and adjustable vibration. Solukon’s unique Smart Powder Recuperation Technology SPR® makes this possible. With digital features like the SPR-Pathfinder® depowdering software and the Digital-Factory-Tool, a sensor and interface kit for process monitoring and automation integration, Solukon systems meet even the highest demands for cleaning quality, process transparency, and digital integration.

Together with this new reseller, URMA, Solukon will further strengthen its already good market position in Switzerland. “The Swiss AM market will continue to gain momentum in the coming years. We are happy to add another industry expert, URMA, to our global sales network,” says Michael Sattler, Global Sales Director at Solukon, who is responsible for the Augsburg-based machine manufacturer’s international sales activities.

Oliver Berner, Director Machines and member of URMA’s management team adds: “In recent years, URMA AG has greatly expanded its 3D printing abilities across the entire manufacturing chain. With Solukon, we have gained a strong partner in the area of postprocessing and a perfect addition to our portfolio of machines. We look forward to a successful cooperation!”