SFM-AT1500-S: the largest metal depowdering solution yet

Solukon, a leader in metal AM depowdering solutions, has just announced a new system, the extra-large SFM-AT1500-S, capable of depowdering parts as heavy as 2100 kg and measuring up to 1500 mm in height. The new heavyweight depowdering system is the company’s largest yet and will undoubtedly open up new levels of efficiency for the post-processing of large-scale metal components. We had the opportunity to chat with Solukon CEO/CTO Andreas Hartmann about the new solution and how Solukon is managing to solve challenges previously associated with powder-based metal AM post-processing through its innovative suite of hardware and software technologies.

“Solukon is the supplier of the largest formats depowdering systems ever since so the company is very experienced in large-format depowdering,” Hartmann says, adding some context about the company’s depowdering expertise. “Solukon started back in 2015, with a system designed for the largest machine on the market at the time, the Xline 2000R from Concept Laser measuring 800 x 400 x 500 mm. As early as 2020, Solukon impressively proved its depowdering expertise in the large-scale part segment again when it launched SFM-AT1000-S, a system that rapidly established itself as the market leader. The comprehensive experiences acquired since then have informed the development of an even larger system for metal parts, the SFM-AT1500-S.”

The challenges of depowdering large-scale metal parts

“Depowdering large components has always been a challenge due to the weight and dimensions of the parts,” Hartmann tells us. “What has made this even more difficult in recent years is that the complexity inside the components is also increasing in the large component segment. This means that automated depowdering has had to keep pace with developments.”

Furthermore, he goes on to explain that much of the current demand for such large-scale, complex metal parts is from highly demanding industries, like aerospace, which require parts that meet exceptionally high standards. He elaborates: “Large components are mainly used in critical industries, such as the rocket industry, where special requirements are placed on component cleanliness. The parts must of course be completely free of powder since some ducts or channels will be filled with liquid fuel or/and liquid oxygen later. Also, space parts are often printed incopper which is a tough depowdering challenge. In copper parts, powder particles tend to clogg in internal channels or cavities and therefore need a special depowdering treatment, e.g. targeted knocking or ultrasonic excitation.”

The new SFM-AT1500-S system addresses these challenges and offers an efficient way to remove the powder even from the most complex large-scale metal prints. The system is designed to remove powder using a fully automated process based on Solukon’s SPR-Pathfinder software and can process reactive metals thanks to the option to work in an inert atmosphere.

Large-scale capabilities in a compact footprint

One of the company’s main priorities when increasing the scale of its depowdering technology was not to dramatically size up the machine footprint. “When developing the machine, the overriding principle was: maximum capacity, minimum footprint,” Hartmann explains. “While the machine can accommodate massive parts with dimensions up to 600 x 600 x 1,500 mm or 820 x 820 x 1,300 mm and weighing up to 2100 kg (incl. the build plate), the system is still as compact as possible.” 

To get into the specifics, the large-scale depowdering system has dimensions of 2,630 x 2,150 x 2,430 mm and requires an installation space of 5,000 x 3,750 x 4,000 mm. The next largest system in the company’s metal portfolio, the SFM-AT1000-S, which can accommodate parts up to a max weight of 800 kg, requires an installation space of 3,600 x 2,600 x 3,500 mm.

This relatively compact footprint was achieved in part through an innovative loading system. “The structure is arranged so flat that no platforms or stairs are necessary to load the parts,” the Solukon CEO adds. “This makes the system unique in terms of its footprint-functionality ratio and particularly safe and convenient when loading and handling large components.”

Better than “good vibrations”

Solukon also had to find a solution for handling the movements and vibrations of such large-scale metal prints, which are necessary to get fine powder particles out of all nooks and internal channels.

“To clean internal cavities, frequency agitation is needed in addition to rotation to make the powder flow,” he says. “Of course, the massive parts must be made to strongly vibrate. However, the pneumatic vibrations must not be transmitted to the rest of the system, which is why Solukon developed a completely new decoupling concept. The part is made to vibrate optimally in any position, while the rest of the chamber is immune to the vibration.”

The pattern of vibration and rotation is not random: Solukon has developed an intelligent depowdering technology enabled by its SPR-Pathfinder software, which programs specific movement sequence based on the part geometry. “With the SPR-Pathfinder software, Solukon systems are the only systems in the world that apply depowdering component-specific and therefore according to the part geometry,” Hartmann adds. “This means that instead of always following the same movement sequence, the Solukon runs the ideal movement pattern for the specific component. This is made possible by a pre-calculation of the SPR-Pathfinder based on the CAD file of the component.”

In practice, this customized powder removal choreography can begin as soon as the CAD file is ready, meaning that users can simulate powder removal before printing the part to ensure that it is fully cleanable. The software can also generate optimized vibrations and movements based on a whole build, rather than a single part. “This means that even if there are different components on a build plate, Pathfinder can calculate it all at once.”

Moreover, the software does not only take part geometry into account, it also factors in the material type and its specific flow properties. All these capabilities result in a depowdering solution that delivers superior cleanliness and reliability, even for the most complex structures.

A glimpse at the SFM-AT1500-S workflow

Hartmann goes into detail about what the workflow for depowdering a large-scale part looks like using the company’s new system. “When the printing procedure is done, the part needs to be freed from the powder cake by vacuuming the powder. Using a forklift, crane or any other lifting device, the part can then be loaded into the Solukon SFM-AT1500-S very conveniently thanks to the front-top loading feature. 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 high flexibility. Also the front door can be opened very widely.”

Once the part has been loaded, the SFM-AT1500-S gets to work, removing all loose and trapped powder from the part. But where does all that powder go? “When depowdering the massive parts, significant amounts of powder accumulate and standard collection containers are too small,” he explains. “With the compatible SFM-PCU powder collection unit, the powder can be safely extracted and collected in a large container in a process monitored by sensors. Also, SFM-AT1500-S can be compatible with powder conveying systems of other manufacturers.”

For enhanced workflow management that extends from printing to downstream post-processing, Solukon also offers the optional Digital-Factory-Tool solution, a sensor and interface fit, which facilitates tracking and quality control. “The processes downstream from printing must flow transparently in order to give users an undistorted picture of the efficiency of their additive production lines. Thanks to the integrated Digital-Factory-Tool, the depowdering procedure in the SFM-AT1500-S is fully transparent to users during the entire cleaning process. These data can be integrated in the overall digital dashboard of the printer via OPC UA.”

Closing a gap

Ultimately, the new SFM-AT1500-S addresses the growing demand for large-scale metal prints from industries like aerospace, new space, defense and transportation. Notably, it also matches the increasing volume capabilities of large-format powder-based metal AM systems, like the NXG XII 600E from Nikon SLM Solutions, which has a build envelope of 600 x 600 x 1500 mm, and the AMCM M8K, a record-breaking eight-laser system with a build size of 800 x 800 x 1200 mm. 

The new depowdering system was launched last week and joins Solukon’s portfolio of other metal AM depowdering solutions, including the SFM-AT200, SFM-AT350, SFM-AT800S and SFM-AT1000S.

This article was published in collaboration with Solukon Maschinenbau GmbH.