As the demand for Additive Manufactured parts continues to grow, the importance of maximizing daily production through 3D printers has become paramount. For companies that have a multitude of 3D printers, ensuring that their uptime is maximized is imperative to generating higher profits. A key to maximizing uptime in this industry is assessing any current bottlenecks and then searching for new methodologies to replace those that have become antiquated.
Recycling of metal powders after the 3D print process has unfortunately become a pain point for many users of these systems. Most 3D printers come with their own recycle box, but these systems struggle with capacity and often cannot even sieve at the original powder spec. This means that companies are left sieving at 74 or 88um when the powder spec is at 44um and there is now a potential for unwanted splatter particles ending up in the product! Furthermore, to get around this, some companies have begun manufacturing stand-alone recycle systems that can move from printer to printer. Unfortunately, these systems are also based on older sieving technologies, and while offering some improvement, they still leave a lot to be desired.
When it comes to recycling powders for 3D printing, ensuring that the powder returns to its original specifications is paramount. This will not only allow users to achieve a longer life of the powder, but it also ensures structural stability of the parts by ensuring there are no unwanted oversized particles being put back into the printer. Cheating the micron hole size may seem like a worthy trade-off as users can get more powder through the system in a shorter amount of time, but there are consequences to this.
As companies install more and more printers, the need for higher capacity out of these recycling systems continues to increase along with it. The faster the powder is recycled, the faster it can be put back into the printer and in turn get back to making companies’ parts. Using a higher mesh size than desired is not the only way to increase capacities, and Elcan Industries has been proving this for the past decade.
The Hi-Sifter Sieving Machine
The Hi-sifter, by Elcan Industries, is the only sieving machine that is capable of recycling metal powders at their original spec without sacrificing rates or yields. Whether it be 107um, 44um, or even 15um, the Hi-Sifter can make these separations in a single pass at rates of hundreds of kilograms per hour. The system was originally designed to help powder manufacturers sieve at 45 over 15um post atomization to develop products for printers, but it is now being used around the world as a recycling system as well. The systems have allowed companies to cut down their recycle time by multiples without sacrificing yield or needing to pay up for replacement ultrasonic meshes.
So, What’s The Difference?
Unlike conventional and ultrasonic sieves, the Hi-Sifter employs high, vertical energy into the screen mesh to make fine separations. There are no balls, sliders, or ultrasonics inside of the machines making it ideal for aerospace and biomedical applications within the AM space. The system employs a tensionless screen cloth that allows companies the ability to change between various different size cloth in a matter of minutes without having to send the frames back to the manufacturer for remeshing. By keeping the powders elevated inside of the system with this energy, the potential for blinding is virtually eliminated while the efficiencies and rates increase astronomically.
The Hi-Sifter can be sold as a standalone system that companies use as a central hub for all their printers. The stainless-steel construction and lack of organic components makes switching between alloys a breeze, while some companies choose to have a dedicated system per alloy. Furthermore, the Hi-Sifter can be incorporated into some existing recycle boxes to immediately upgrade the throughputs and efficiencies or these systems. Elcan is working closely with customers to develop an additive manufacturing recycle box that will include the Hi-Sifter as well, and this unit is currently available for pre-order in the marketplace as well.
Elcan Industries has a full-scale testing and tolling processing services facility where companies can send powders to trial any of the systems available. The Hi-Sifter is available at 400mm, 700mm, and 1000mm and offers a multitude of different configurations based on the users’ needs. We welcome any screening challenges and invite customers to send us powders so they can experience the added performance benefits of these advanced systems.
For more information on our advanced recycle box systems contact us today!
📞1-800-AT-ELCAN (1-800-283-5226)
Hi-Sifter Features & Benefits
- Cost Savings: By recycling powders, companies can reduce their overall material costs and improve the cost-effectiveness of the additive manufacturing process.
- Reduced Waste: Powder recycling reduces the amount of waste generated during the additive manufacturing process, contributing to a more sustainable production process.
- Improved Product Quality: Recycling powders ensures that only the highest quality materials are used, leading to higher quality final products.
- Increased Production Efficiency: By recycling powders, companies can reduce the amount of time required to produce a given number of parts, resulting in increased production efficiency.
- Enhanced Safety: By recycling powders, companies can minimize the risk of contamination and ensure that only safe, high-quality powders are used in the additive manufacturing process.
- Better Resource Utilization: By reusing powders, companies can reduce the amount of resources needed to produce parts, leading to a more sustainable and environmentally friendly production process.