New standards in the cleaning and post-processing of 3D-printed metal components: With the SFM-AT1000-S from Solukon, the Austrian 3D printing pioneer frees internal channels and cavities of the most complex parts from powder residues. The system recently went into operation at the company’s headquarters in Austria.

The next step for M&H towards becoming one of the Central European innovation leaders in the field of additive manufacturing: With the SFM-AT1000-S depowdering system from the German quality manufacturer Solukon, the Styria-based 3D printing pioneer is setting the next qualitative exclamation mark. The automatic powder removal system is specially designed for cleaning and post-processing 3D-printed parts. In particular, large and heavy metal components with a height of up to 1,000 mm and a maximum weight of 800 kg as well as tasks with particularly high post-processing requirements can be freed from powder residues particularly efficiently on the powder removal system.

Removing powder residues from complex geometries

For M&H-CEO Patrick Herzig, the key benefit lies in the precision of the system: “With the Solukon system, we can efficiently and thoroughly remove powder residue from complex parts with internal channels and cavities. This feature is a decisive advantage, as such complex geometries often present a challenge in post-processing and powder residues in the components could mean a loss of performance. With the introduction of the
SFM-AT1000-S, we are setting new standards in the post-processing of 3D-printed parts in titanium, aluminum, stainless steel and materials such as Scalmalloy and Inconel. This technology enables us to further increase the quality of our products and make our production processes more efficient and even safer through series cleaning.” Technologically, this is realized by two endlessly rotating axes with servo drive – the component thus moves along the programmable path. A built-in high-frequency knocker also loosens powder clumps in particularly narrow channels. For reactive materials, the Solukon SFM-AT1000-S can be inerted with inert gas – the process offers maximum explosion and health protection.

“The SFM-AT1000-S, sets new standards in the manufacturing industry – also thanks to its compatibility with our innovative SPR-Pathfinder® software. With this unique software, individual motion patterns can be calculated automatically for each component based on the CAD file. By optimizing and automating their post-processing procedures, we offer our customers – like M&H – a clear competitive advantage. With the Digital-Factory-Tool, a sensor and interface kit, our partners also have maximum transparency over the depowdering process,” explains Andreas Hartmann, CEO and CTO of Solukon.

Post-processing for Formula 1 components

At M&H, the SFM-AT1000-S is used to post-process components for the aerospace and international racing industries in particular – especially Formula 1: “The ability to clean components with extreme precision enables us to meet the specific and stringent requirements of these industries, where precision and reliability are particularly crucial. Using the SFM-AT1000-S from Solukon ensures that even the finest geometries can be reworked without compromising on quality,” emphasizes M&H-CEO Herzig. Especially in combination with the SLM 800 3D metal printer (build volume: 500 x 280 x 850), which is also new, M&H is now “particularly well positioned for the production of complex components in large dimensions”, says Herzig.

American aerospace company Launcher has announced Solukon as its preferred supplier for powder removal systems. Within the scope of the partnership, Launcher will utilize Solukon’s machine, the SFM-AT1000-S, for the postprocessing of extraordinary large and heavy rocket parts. Solukon’s depowdering system offers fast and efficient removal of metal powder for applications of up to 1,000 mm height.

The postprocessing of components in the Additive Manufacturing process is a significant step. Due to complex geometric shapes and, for example, internal cooling channels or internal structures, depowdering can become complicated and time-consuming. In addition, users are faced with risks including explosion, occupational health, labor costs, powder recovery, cleaning quality and process repeatability. Copper (CuCrZr), the material of choice at Launcher due to its high conductivity and efficient cooling, poses a particular depowdering challenge as copper powder residues tend to clog in cavities and show a sticky behavior. In addition, manual cleaning obviously reaches its limits when it comes to rocket parts with a height up to 1,000 mm weighing several hundred kilograms.  

SPR® Technology for a safe and reliable depowdering

Solukon tackles these issues with its unique SPR® technology (Smart Powder Recuperation). The SFM depowdering systems remove residual and clogged powder from metal laser melted parts within a sealed process chamber, using adjustable vibration and automated two-axis part rotation while recovering superfluous powder. Through programmable rotation of the build plate in two axes, unfused metal build material is completely removed from complex channels and geometries, meaning a significant increase in efficiency, safety and quality – all while saving on costs.

SFM-AT1000-S becomes part of the Launcher fleet

Launcher from now on relies on the postprocessing knowledge of Solukon. They acquire the depowdering system SFM-AT1000-S, the unit for extraordinary large parts, to completely free rocket engines and combustion chambers from powder. Launcher, located in Hawthorne, California, is an industry-leading developer of highly efficient rockets and transfer vehicles. The company currently operates a fleet of cutting-edge metal additive platforms and other advanced manufacturing assets from partners including Velo3D, EOS and AMCM. Today, Launcher produces every major part of its transfer vehicle, Orbiter, and E-2 liquid rocket engine in-house, as part of its strategy to build, test, and iterate as cost-effectively as possible as it develops high-performance rockets and transfer vehicles.

“We’re happy to include the state-of-the-art system for depowdering to our outstanding AM fleet”, says Max Haot, founder and CEO of Launcher. Tim Berry, Launcher’s Head of Manufacturing, adds: “We see that automated powder removal is an essential step in the production process. For final heat treatment and Hot Isostatic Pressing all parts must be free of any powder, a special challenge for large and heavy parts with hard-to-access internal channels. The SFM-AT1000-S will help to further automize our production process as we achieve reliable and repeatable cleaning results. In addition, we benefit from Solukon’s experience and support when optimizing our fast and forward-thinking production lines.”

Launcher acquires a perfect-fit postprocessing system for rocket parts

The one-meter-high Launcher E-2 engine, first time presented in 2019, was made in Germany by AMCM using its specialized M4K printer. With the purchase of the SFM-AT1000-S through Launcher, the wheel has come full circle as this Solukon system was initially developed at the request of AMCM for a depowdering solution for parts exactly from this M4K printer.

The Solukon SFM-AT1000-S, an advancement of the SFM-AT800-S-system and a special version particularly designed for large and heavy parts, allows to easily move parts with a size up to 600 x 600 x 1.000 mm (XYZ) with a weight up to 800 kg. This makes it the ideal postprocessing system for the Aerospace & Space industry. The SFM-AT1000-S has two endless rotating axes with programmable servo-drives so that it can move the part along any imaginable path. Individual control is also possible by using a joystick to move the component flexibly in any direction at variable speed and to save the movement pattern afterwards. The optional Digital Factory tool enables quality assurance and automation integration of the depowdering process.

“Yet again, it’s an honor to support a leading New Space company with our SPR® technology. Shortly after the demand for a machine compatible with the AMCM M4K printer came up, we responded directly by developing the SFM-AT1000-S. I’m sure pioneers like Launcher will keep pushing the boundaries of what’s possible in Additive Manufacturing. Likewise, I’m sure we’ll always stand by their side with the ideal depowdering solution”, says Andreas Hartmann, CEO and CTO of Solukon.

Official deal at Rapid + TCT show in Detroit, MI

Solukon and Launcher will officially announce their partnership at Rapid + TCT show in Detroit, Michigan (May 17-19). Visitors will have the opportunity to explore the Launcher system live and in color at the Solukon booth 2137. The Solukon team is looking forward to seeing you there.