Automated post-processing for ColdMetalFusion components: AutoSmooth project completion

Together with Rösler Oberflächentechnik GmbH and Headmade Materials GmbH, Neue Materialien Bayreuth GmbH (NMB) developed an automated process for the depowdering and surface smoothing of ColdMetalFusion green parts as part of the “AutoSmooth” research project. The aim of the project was to specifically improve the surface quality of the components before debinding and sintering and to significantly reduce the post-processing effort otherwise required only on the finished metal component.

To this end, an automated process was developed that combines the depowdering of the printed green parts with targeted surface smoothing. Processing in the green state makes it possible to reduce surface irregularities at an early stage. As a result, the components have significantly higher surface quality after sintering, while the effort required for subsequent surface finishing is considerably reduced.

In addition to optimizing component quality, the project also investigated the reusability of the feedstock used. The results show that the powder recovered after the additive manufacturing process and the AutoSmooth process can be reused without any relevant loss of quality. The nearly closed material cycle reduces the loss of valuable materials and increases the resource efficiency of manufacturing.

The investigations on green and sintered components also demonstrate the positive influence of automated post-processing on component quality. By reducing surface defects and notch effects, the stability of the green parts was increased. At the same time, the sintered components have a more homogeneous surface layer while maintaining high material quality and density.

In addition, the entire ColdMetalFusion process chain was evaluated with regard to economic viability, material efficiency, and environmental impact. The results show that automating green-part post-processing can significantly reduce processing times, costs, and resource consumption. Particularly for larger production volumes, the lower post-processing effort and high degree of automation offer considerable economic advantages.

With the knowledge gained in the project, the project partners are creating an important foundation for the further industrialization of ColdMetalFusion technology and its use in economically viable and resource-efficient series production of complex metal components.

Funding: Bavarian State Ministry of Economic Affairs, Regional Development and Energy (StMWi) as part of the Bavarian Collaborative Research Program (BayVFP), funding line “Materials and Raw Materials”.