1
Case Study AutoSmooth
Automated Post-Processing for ColdMetalFusion
The project aims to automate the post-processing of ColdMetalFusion (CMF) green parts, whose limited mechanical stability has so far required manual depowdering. The core of the project is the development of an automated process with a high powder recovery rate. By integrating surface treatment in the green part state, the surface quality is specifically improved, and the effort for subsequent processing steps is significantly reduced. In addition, the effects of powder aging on the properties of the feedstock are systematically investigated. The goal is to define robust process parameters and create an economically and ecologically viable overall solution for series production.
Approach
Motivation
Manual Post-Processing Hinders the Economic Viability of the CMF Process
The ColdMetalFusion (CMF) process offers great potential for the cost-effective production of complex metal components as an innovative, powder-based manufacturing process. However, a significant obstacle to industrial use lies in the challenging handling of the so-called green parts: These have low mechanical stability compared to the metal component, making established depowdering and smoothing processes from polymer processing non-transferable.
Currently, manual post-processing is necessary, leading to high personnel costs, low throughput rates, and poor reproducibility. As a result, the economic viability and scalability of the overall process are significantly limited. To fully exploit the potential of the CMF process, a systematic and automated solution for the post-processing of green parts is required.
Solution Approach
Automated Depowdering and Smoothing for CMF Green Parts
The AutoSmooth project is developing an automated post-processing procedure for ColdMetalFusion green parts that transfers the previously manual process steps of depowdering and smoothing into a continuous, reproducible system solution. The central goal is to establish a gentle, mechanical surface treatment that enables reliable powder removal despite the low strength of the green parts while achieving a high recovery rate.
Additionally, a deeper understanding of powder aging along the process chain is being developed, particularly regarding the interactions between feedstock and laser system. The insights derived from this will contribute to targeted process optimization and an economic as well as ecological assessment of the entire CMF process chain. Thus, AutoSmooth makes a significant contribution to the automation and industrialization of the CMF process.
Approach
Automation and Optimization of the Post-Processing Processes of the CMF Process
- Development of an Automated Post-Processing Process
Concept and implementation of a continuous process for combined depowdering and smoothing of CMF green parts using mechanical technologies, adapted to their high sensitivity. - Characterization of Powder Aging Along the Process Chain
Experimental analysis of physical and chemical aging processes in the powder material, considering key influencing factors such as temperature, humidity, storage duration, and thermal stress during the manufacturing process. - Investigation of Interactions Between Feedstock and Laser Process
Systematic collection and evaluation of the interactions between the material properties of the powder feedstock and the process parameters of the SLS process to specifically control their influence on green part stability and subsequent component quality. - Ecological and Economic Assessment of the Automated Process
Conducting a comparative analysis regarding energy and resource use, economic viability, and scalability compared to previous manual post-processing steps.
With AutoSmooth, a comprehensive approach for the automated post-processing of green parts in the CMF process is being developed – with the aim of making processes more efficient, sustainable, and industry-oriented.
Project sponsor: Bavarian State Ministry of Economic Affairs, Regional Development and Energy | Funding code: MW-2112-0007
Partners: Rösler Oberflächentechnik GmbH, Headmade Materials GmbH