New surface finishing solution

With its latest development of a new media type for post processing of thermoplastic components, printed with the MJF and SLS technology, AM Solutions – 3D post processing technology is further expanding its product portfolio. The new media permits the safe, cost-efficient finishing of 3D printed components with different shapes and sizes in one single process step and with absolutely repeatable results. This eliminates the time-consuming and costly media changes for different processing stages. In combination with the respective printing knowhow the new media mix generates a perfect, finely structured and highly homogeneous surface finish.  

With the growing utilization of additive manufacturing for volume production of plastic components the requirements for cost-efficiency and high-quality surface finishes are becoming more demanding. With a team of experts in the field of automated post processing the Rösler brand AM Solutions – 3D post processing technology is meeting this challenge head-on. The latest development is a media that generates absolutely repeatable, high-quality finishing results on thermoplastic components, which are printed with the powder-bed-based printing technology MJF and SLS. For this novel product the AM Solutions experts took advantage of the comprehensive development knowhow of the Rösler Oberflächentechnik GmbH. With more than 15,000 products Rösler offers by far the largest portfolio of media and compounds in the world.   

High versatility makes finishing processes simpler, safer and more cost-effective

The material, shape and size of the new media has been perfectly adapted to the post processing requirements of 3D printed plastic components. Christoph Bätz, Project Engineer at AM Solutions – 3D post processing technology explains: „The composition of the new media mix was developed through numerous processing trials. The result is a product that allows the surface finishing of a broad spectrum of components with different shapes and sizes. Irrespective of whether small, delicate work pieces or large components must be treated, the result is always a highly homogeneous, consistent and repeatable finish.” The grinding performance depends on the geometrical complexity of the work pieces. For certain applications the surface roughness can be reduced from Ra = 15 μm to Ra = 3 μm within 240 minutes.   

Multi-stage finishing processes require frequently multiple media changes. Since the new MJF/SLS media already contains an optimum mix of different shapes and sizes, the need for such changes could be completely eliminated. Maintaining the correct processing sequence is also no longer necessary. This facilitates the overall handling considerably. In addition, since the new media type can be used for a broad range of applications, stocking multiple media types for different work piece categories is no longer needed. This represents a significant cost saving.  But a higher cost-efficiency is only one part of the story. The new media also helps improve the stability and safety of the finishing processes. Of course, a significant factor is also the consistently high quality of the ceramic media, which is guaranteed through a mostly digitized and tightly controlled manufacturing process. Rainer Schindhelm, Division Manager for the Production of Consumables at Rösler Oberflächentechnik GmbH comments: „Decades of valuable experience allow us to continuously develop new products that offer a significant added value for our customers and provide solutions to the challenges they have to face. The perfectly adapted interaction between machine, consumables and process knowhow makes the innovative, unique solutions of Rösler and its brand AM Solutions – 3D post processing technology highly successful”.   

Efficient surface grinding of extremely delicate components without causing any damage  

The surface finishing of particularly delicate work pieces with complex geometries poses especially demanding 3D post processing challenges. In combination with optimized printing methods, the new media mix generates highly homogeneous results for these difficult finishing tasks. At the same time it minimizes scrap and saves costs. The experts from AM Solutions – 3D post processing technology will be able to assist you with the engineering for such optimization measures.