Since 2021, Sauber Applied sciences and AM Options have been intently cooperating within the discipline of additive manufacturing. For the post-processing of 3D-printed steel and plastic parts, Sauber is using a number of machines equipped by AM Options. These extremely environment friendly post-processing items had been specifically tailored to the technical necessities at Sauber Applied sciences.
Sauber Applied sciences, recognized for its high-value 3D print options for Formulation 1 racing vehicles and different industries, has been efficiently cooperating with AM Options for a number of years. For instance, roughly one yr in the past the corporate bought an S1 shot blast system for post-processing of HiPAC parts produced with the SLS printing know-how.
The S1 gives a major technical benefit by performing the post-processing steps of cleansing and floor ending in a single machine, with just one blast media. The machine additionally handles parts very gently – particularly vital when extraordinarily delicate parts with advanced shapes have to be processed.
“For the reason that S1 system can deal with a number of features, it reminds us of a little bit of the multi-functionality of a Swiss military knife. Whereas previously we needed to manually rework and shot blast the printed parts individually, at the moment we solely must take away the completed components from the S1 and visually examine them. With a mean batch dimension of 20 workpieces we save at the very least two hours of precious time per post-process cycle,” stated Vitor Sousa, staff chief for AM of plastic parts at Sauber Applied sciences AG.
The blast media used within the S1 post-processing system is constructed from polystyrol. “Up to now, we used glass beads, which had been cheaper. However due to their excessive put on fee, they’d a significantly shorter life span. The polystyrol media gives a 15 occasions greater usable life – leading to considerably decrease working prices. An extra profit is that in comparison with glass beads the polystyrol media creates extra enticing and glossy floor finishes. As well as, we should not have to vary the blast media for the method steps [of] ‘cleansing’ and ‘floor ending’. And the chance of media contamination through the use of two totally different media has been fully eradicated,” stated Sousa.
The excessive uptime of the blast media is ensured by the S1’s refined media cleansing and recycling system. The optimum tuning of the filter items, cyclone, and media display ensures the dependable separation of residual powder from the blast media. The media cleansing and recycling system additionally reduces the quantity of waste and makes all the course of extra sustainable. Lastly, with its decrease abrasivity, the polystyrol media produces a better uptime of vital tools parts and thus simplifies upkeep and reduces working prices.
A custom-engineered answer
“As a result of in our manufacturing space area could be very tight, the usual S1 system was too massive to suit into our setup. Subsequently, we would have liked an answer with a decrease footprint,” stated Sousa. To satisfy this problem AM Options modified the S1 idea by making a cell mud collector. Such engineering flexibility is feasible, as a result of AM Options develops and produces its tools in-house at its Untermerzbach location, in Germany. The corporate additionally developed one other particular space-saving model of the S1 for the therapy of white SLS materials at Sauber Applied sciences.
By processing the white SLS and the black HiPAC parts in separate machines, the chance of discoloration was reportedly fully eradicated. “With AM Options we’ve got a accomplice who gives not solely normal tools however who completely understands our necessities and gives us with tailored options,” stated Sousa. Different engineering developments between the 2 firms are already on the drafting board.
The S1 is offered to see in AM Options’ Buyer Expertise Centre (CEC) in Knowsley, UK.