Stratasys launches SAF ReLife software solution

Stratasys has launched SAF ReLife, an innovative software-based solution that transforms waste PA12 powder from other additive manufacturing technologies into high-quality parts. The SAF ReLife solution can efficiently repurpose waste PA12 powder from powder bed fusion printers, including high-speed sintering, SLS (selective laser sintering), and jetting build processes for use within the Stratasys H350 printer. This sustainable solution helps customers produce high-quality surface-finished parts with powder that is otherwise considered waste. This new technology can significantly lower the cost-per-part for customers; improve their material efficiency; and reduce their overall carbon footprint per build.

“SAF ReLife gives customers a unique ability to make high-quality parts with powder considered waste from other polymer powder bed fusion processes,” said Neil Hopkinson, Vice President of Additive Manufacturing Technology at Stratasys. “Our patented unidirectional print-and-fuse architecture and thermal control uniquely enable this capability at production volumes.”

Service bureau Wehl Green beta tested SAF ReLife by utilizing their SLS waste to their SAF ReLife. The company reported significant savings of 20% in total cost per part and a substantial reduction in waste by turning unused powder into functional parts through a repeatable process using SAF technology. In addition, Wehl Green has been able to turn around new parts and have them delivered within 48 hours for customers.

“By utilizing the SAF ReLife technology, we’ve cut production costs while producing parts that meet strict industrial specifications. It’s a game-changer for our competitiveness,” said Javier García, Manager and Co-founder of Wehl Green. “Thanks to Stratasys’ SAF ReLife project, we’ve been able to turn PA12 waste into high-quality parts. This circular economy approach has reduced our environmental impact while maintaining top-tier product standards.”

SAF ReLife is a breakthrough in addressing the common challenge of what to do with aged powder. To determine the environmental impact, Stratasys partnered with Fraunhofer IPA to conduct a third-party Life Cycle Assessment (LCA) to validate the environmental benefits of SAF ReLife. The study revealed that repurposing PA12 waste from powder bed print processes in SAF production can reduce carbon footprint by up to 89%, compared to standard production with polyamide 12 material.

“Our life cycle assessment demonstrates that Stratasys’ SAF ReLife PA12 solution can reduce the carbon footprint of the reference print job by 43% with the German electricity mix and by as much as 89% when powered by renewable energy sources, compared to standard PA12,” said Chantal Rietdorf, M.Sc., Research Associate at Fraunhofer.