Voxeljet shows recycled PA12 powder can be fully reused in HSS

Voxeljet AG, Dressler Group GmbH, Fraunhofer IPA, and the University of Bayreuth have successfully collaborated on a study proving that waste PA12 nylon powder, commonly discarded in 3D printing, can be efficiently recycled and reused. Utilizing HSS (High-Speed Sintering) technology on voxeljet’s VX200 HSS platform, the partners demonstrated that reclaimed PA12 powder can perform as well as, or even better than, fresh material in selective laser sintering (SLS) systems. This breakthrough not only supports circular economy goals but has the potential to address up to 50% of running costs in additive manufacturing.

Recycling nylon powder directly addresses the cost and environmental impact challenges of traditional 3D printing processes. Powder expenses alone can account for half of a 3D printer’s operating costs, especially in large-scale manufacturing. By enabling the reuse of PA12, the study has set a precedent for significant cost savings and reduction of waste in additive manufacturing. “The future possibility of processing this recycled powder on larger production platforms like the VX1000HSS will bring immense cost savings,” saisd Tobias Grün, Global Product Management at voxeljet.

In SLS 3D printing systems, PA12 nylon powder is repeatedly exposed to high temperatures, causing the powder to degrade, lose its flowability, and alter its melt viscosity. As a result, only a portion of the powder can be reused, leading to significant waste. Addressing this challenge, the collaborative study focused on reconditioning this waste powder for 3D printing through voxeljet’s High-Speed Sintering (HSS) platform. Unlike laser-based systems, HSS uses an inkjet printhead and infrared heating to provide a selective and gentle energy input, enabling gradual sintering without the adverse effects associated with laser technologies.

High-Speed Sintering, a process pioneered by voxeljet, allows for flexible adjustments to powder and process parameters, making it a suitable platform for recycled materials. Dressler Group processed the used PA12 powder to restore its key properties, such as flowability and moisture content, ensuring it was fit for reuse. The recycled powder was then successfully printed by Fraunhofer IPA, confirming that the powder maintained or even exceeded the properties of fresh material. Jan Kemnitzer, Fraunhofer IPA Research Team Lead, commented, “The VX200 HSS technology is an open-source system, allowing us to quickly adapt to any powder with consistent results.”

The collaborative study presents a viable approach to incorporating circular economy principles in 3D printing, reducing operational costs while promoting sustainability. The results of this study will be showcased at the Formnext trade show in Frankfurt, Germany, from November 19th to 22nd.