Rösler is a well-established agency historically recognized for its mass ending and shot blasting options; through AM Options the corporate has additionally firmly established itself within the discipline of additive manufacturing.
I spoke to David Soldan, Head of AM Options – 3D post-processing expertise, and Volker Löhnert, Managing Director, Rösler Oberflächentechnik GmbH, about how this new avenue invigorates the agency’s revolutionary spirit.
Round 4 years in the past, Rösler acknowledged the transformative function of 3D printing as a “new manufacturing methodology for metallic and plastic elements” and noticed the standard subsets of their enterprise rising alongside a burgeoning array of 3D printed merchandise. Löhnert recalled how prospects approached them for options tailor-made to 3D printed elements, which he famous had “a floor a lot rougher than casting.” He emphasised the contrasting nature of 3D printing environments to conventional casting settings, which led the corporate to understand that its customary options won’t suffice on this new area.
Soldan confused adapting to the distinctive necessities of 3D printed elements. In contrast to conventional manufacturing processes, the post-processing of 3D printed merchandise required dealing with of powder, coping with rougher surfaces, and even venturing into chemistry inside post-processing machines. The main target is on revolutionary 2-in-1 options that enhance the effectivity and high quality of post-processing of 3D-printed merchandise, as they streamline the whole course of chain and considerably scale back the associated fee per piece. Such an method permits the corporate to completely fulfill the necessities of consumers who’re searching for high-volume manufacturing with 3D printing applied sciences.
Löhnert additionally touched upon their in depth expertise with consumables and chemical substances within the mass ending course of, emphasizing the agency’s readiness to switch this data to the 3D printing area. This enterprise, they hope, won’t solely increase Rösler’s footprint however may even deliver forth options that resonate with the evolving calls for of the market.
Learn extra within the 3D Printing Business Government Interview sequence.
AM Options Integrative Method: Streamlining Put up-Processing in 3D Printing
As Rösler/AM Options ventures deeper into the additive manufacturing area, David Soldan and Volker Löhnert define their revolutionary method in direction of streamlining post-processing procedures, by an array of mass ending and shot blasting processes and, extra just lately, by chemical processes.
Soldan revealed that the corporate’s focus is on 2-in-1 options, which assist scale back the price of AM post-processing and streamline the method chain, which is key to making sure AM will get correct traction throughout {industry} as a viable quantity manufacturing expertise. Combining totally different processes in a single machine not solely saves on capital funding, can be reduces machine footprint and simplifies the post-processing steps within the AM course of chain.
Löhnert accentuated the essential want for standardization within the face of many printers and fashions out there. He said, “It’s additionally arduous to seek out the only post-processing resolution, which inserts all,” underlining the complexity that post-processing specialists like AM Options are navigating.
Soldan additionally highlighted an ignored problem – the shortage of schooling and experience in additive manufacturing on the store flooring, urging a extra sturdy academic framework to domesticate a brand new era of additive specialists.
Löhnert highlighted AM Options’ proactive engagement with main printer producers reminiscent of HP or EOS and energy customers like Protolabs, Weerg, Shapeways or FKM Additive Manufacturing higher to grasp the dynamics and desires of the {industry}. He talked about, “We’re talking and cooperating with a few of the world’s main printer producers to grasp their pondering,” demonstrating a collaborative spirit to develop merchandise and processes that cowl a broad spectrum of functions. Additional, their alliance with native universities goals to highlight the significance of post-processing, nurturing a ‘prepared for post-processing’ mindset amongst budding engineers.
Soldan underscored the crucial of contemplating the whole course of chain proper from the design stage, saying, “Now we have to grasp that our prospects must have an eye fixed on the entire course of chain.” He identified that always, the main focus is skewed in direction of decreasing printing prices, overlooking the cumulative prices incurred throughout guide post-processing and dealing with. The emphasis, he instructed, needs to be on a holistic view of the method chain, doubtlessly investing extra time within the printing course of to reap advantages in post-processing.
AM Options’ Progressive Leap: Introducing C2, the Twin-Motion Chemical Smoothing and Dyeing Machine
Highlighting the corporate’s “2-in-1 course of,” Soldan talked about that the C2 machine for polymer elements produced on the SLS and MJF powder mattress processes embodies this ethos.
The C2’s revolutionary 2-in-1 Liquid Colour Smoothing course of is able to smoothing and dyeing elements in a single move. The result’s a streamlining of the method chain, with each capabilities being carried out by just one machine. It additionally reduces the full capital funding required and lowers the associated fee per completed half. In comparison with different options, the immersion smoothing expertise used reduces the processing time and the specifically developed course of media operates in a extra eco-friendly method.
The C2 machine is emblematic of AM Options’ forward-thinking method, marrying chemical smoothing and dyeing processes into one seamless step. Soldan shared, “The massive benefit is all the things in a single step,” indicating a big discount in guide intervention and machine transitions, historically bloating the post-processing chain.
Discussing the market readiness and scaling of additive manufacturing, Soldan identified the hurdles of lacking requirements and the wide range of distributors, making post-processing a custom-made endeavor. He emphasised, “the entire {industry} collectively must deliver down prices,” which is the philosophy driving the C2’s “2-in-1” design. It’s not nearly mechanical integration; it’s a few complete discount in operational prices, power consumption, and manpower.
Löhnert added the broader goal is to merge processes to simplify operations and decrease technological footprint. He acknowledged present market techniques for smoothing and dyeing as not being the “actual finish resolution” as a consequence of their advanced and doubtlessly hazardous dealing with. AM Options endeavors to make chemical smoothing extra user-friendly and safer.
Unveiling Hidden Prices: AM Options Sheds Mild on Handbook Dealing with Bills in 3D Printing
David Soldan and Volker Löhnert explored the financial influence of guide dealing with within the post-processing of 3D printed elements. Whereas exact quantification stays elusive as a consequence of various circumstances, Soldan estimated that post-processing may account for as much as almost half the full product price.
Delving into the scaling of additive manufacturing (AM), Soldan famous a sustained demand on the polymer facet, though metallic is gaining traction. The expansion is especially evident in sectors like automotive, medical, and aerospace, with Löhnert particularly mentioning the uptick in aerospace and medical sectors on the metallic facet.
The dialog additionally touched on the definition of scaling inside the context of AM, hinting on the want for a deeper exploration to grasp the evolving dynamics higher.
Addressing the definition of scaling inside AM, Löhnert defined that the range in manufacturing volumes throughout prospects is huge. He identified a report from AMPOWER (2023) that the general additive manufacturing market is valued at €9.5 billion in 2022, with a projected compound annual progress fee of 17.7% till 2027. He confused that the present guide post-processing is a “showstopper” for increased productiveness, urging a shift in direction of automation.
Soldan and Löhnert emphasised the need for industry-wide collaborations to outline requirements and scale back prices. Soldan remarked, “The entire {industry} has actually to work collectively to deliver the associated fee down. If an additive manufactured half doesn’t present further benefits on high quality or no matter, the person appears at price per piece. And when conventional elements are cheaper, customers will produce with conventional strategies.”
Regardless of the attract of million-part manufacturing runs, the duo acknowledged that the {industry}’s core is decreasing prices, primarily incurred in post-processing. “Now we have to deliver prices down. Some prospects are already there, however it’s only a few, and the bulk continues to be in some smaller batches, small sequence manufacturing, and nonetheless a whole lot of speedy prototyping,” Soldan said.
Highlighting their distinctive place as a comparatively new firm nested inside the 80-year-old Rösler Group, Löhnert emphasised the agility and long-term imaginative and prescient that units AM Options aside from different post-processing suppliers. “Quarterly experiences to exterior stakeholders don’t drive us. We’re an unbiased family-owned firm and may make our choices concerning prospects,” Löhnert famous, underscoring their customer-centric method.
On geographical focus, Soldan identified Europe and the US as their major markets, albeit with a watchful eye on China’s burgeoning 3D printing panorama. The discourse additionally touched on sustainability, with Löhnert outlining their efforts to attenuate power consumption each in machine design and operation.
Navigating the Expertise Conundrum: AM Options’ Quest for Flexibility in 3D Printing Put up-Processing
The dialog touched on the technical hurdles the agency encounters because it endeavors to streamline post-processing in 3D printing. Because the {industry} strikes in direction of extra environment friendly printing, post-processing stays a crucial but difficult part. Soldan emphasised the inherent complexity, noting, “A few of our prospects don’t know what they are going to print subsequent month, however the processing resolution wants to suit,” indicating a necessity for flexibility in post-processing options.
Whereas the tempo of innovation inside the market is brisk, Löhnert is optimistic concerning the {industry}’s trajectory, foreseeing 3D printing claiming extra territories in industrial manufacturing. Nevertheless, he confused that regardless of the developments in printing effectivity and high quality, post-processing stays indispensable. “There’s all the time post-processing essential to make the floor proper,” he remarked.
As new verticals emerge, the executives see important alternatives, particularly because the {industry} migrates in direction of producing 1000’s of elements every day. The shift necessitates scaling up not solely on the printing facet but in addition on post-processing, an space AM Options is eagerly eyeing. “We’re prepared for scale-up,” asserted Soldan.
Löhnert laid out the imaginative and prescient for AM Options, aiming for a fame such that relating to post-processing, prospects’ ideas gravitate in direction of their options. The objective is to align with prospects’ wants regarding floor high quality and automation in processing.
In a concluding observe, Soldan underscored AM Options’ distinctive place as a bona fide machine producer that handles each facet of machine manufacturing in-house, from laser chopping to 3D printing. He stated, “This offers us additionally the chance to take heed to our prospects in the event that they want one thing particular, which isn’t customary.” This in-house mastery, in response to Soldan, units AM Options aside within the post-processing panorama, poised to drive important progress within the 3D printing {industry}. With an eye fixed on future market developments, the agency is invested in making certain post-processing doesn’t turn out to be the bottleneck within the broader manufacturing course of chain.
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Featured picture reveals AM Options’ put up processing portfolio. Photograph through AM Options.
