AM-MPRR Overview

The 3R’s—REclaim, REclassify & REcondition — are setting a new benchmark in additive manufacturing, driving efficiency, sustainability, and innovation. By utilizing advanced technologies, this approach ensures optimal reconditioning of metal powders, automating material handling, reducing waste, and supporting eco-friendly practices.

HOW IT WORKS

Reclaim, reclassify, and recondition metal powder faster and more efficiently. The AM-MPRR system is the latest collaborative project of GEMCO, VAC-U-MAX and Vorti-Siv. Designed to fully extract, sieve, and recondition metal powders, this system dramatically reduces processing time while ensuring a cleaner, safer, dust-free operation.

By using a VAC-U-MAX Vacuum Conveyor, operators efficiently remove powders from the build box.

The powders are then sieved by a VORTI-SIV screener, separating foreign debris and capturing reusable material.

From there, the powder is transferred to a GEMCO Blender for homogenization, or a GEMCO Dryer to eliminate moisture and restore optimal flowability.

With 85% faster processing, ergonomic operation, and integrated UL-Certified Controls, the AM-MPRR automates metal powder recovery.

85% OF PROCESSING TIME SAVED

100% PERFORMANCE AS PROMISSED

REclaim: Efficiently recover left over metal powders from the build-box by vacuum conveying material in a contained process, eliminating manual handling, and significantly reducing operator exposure to metal powder dust. Once the powder is extracted, the system separates the metal powder from the air-stream and deposits it directly onto a sieve. The sieve removes oversized agglomerations and foreign debris, with the refined metal powder vacuum conveyed to a tumble blender for further processing and reconditioning.

REclassify: Leftover material is screened, separating particles based on size while ensuring volume consistency. The sieve is equipped with an ultrasonic anti-blinding mechanism, creating vibrations that encourage powder movement. This process helps smaller particles pass through the mesh while larger particles or contaminants remain on top. The mesh size, typically 63 micron, determines the maximum particle size that can pass through the sieve.

REcondition: Thanks to GEMCO technology, reconditioning metal powders allows leftover material from the build-box to be restored and reused. One of the most effective methods for this process is tumble blending, which enhances powder consistency and performance. Once reclaimed and reclassified, the metal powder enters the tumble blender for homogenization.

GEMCO tumble blenders use a gentle rotating motion within a sealed vessel to evenly mix the powders, addressing common challenges such as segregation, homogeneity, and surface oxidation. Homogenization ensures a consistent particle distribution, promoting uniform flow behavior. Surface oxidation is mitigated by blending powders with flow agents, which reduce oxidation and restores flowability. Residual metal powders from multiple 3D printers can be combined and homogenized into a consistent masterbatch for reuse.

Advanced GEMCO tumble blenders also incorporate drying systems to lower moisture content to single-digit levels, further improving powder flowability. Additionally, heat and gas purging can be integrated to optimize powder reconditioning.

Safety Features:

  • Grounding Systems: Integrated throughout the blenders, dryers, and recycling units to prevent static discharge.
  • GEMCO Vacuum Tumble-Drying: Utilizes an inert atmosphere to protect the powder and handle potentially explosive dust safely.
  • Adjustable Temperature Ranges: Customizable to meet specific client requirements, ensuring optimal processing conditions.

Benefits:

  • Efficiency: Cuts processing time by 85%, increasing overall productivity.
  • Cost Savings: Reduces costs by recycling and reconditioning metal powders.
  • Environmental Impact: Minimizes waste and promotes sustainability through efficient recycling processes.

Potential ROI for a Gemco (AM-MPRR)

How Critical is this to you? 

Assumptions  

  • Material – Titanium powder (Ti-6AI-4V) 
  • Material density – 280 lbs./ft3 
  • Cost $700/kg ($1317.50/lbs.) 
  • Unit for Reclamation – AM-MPRR Utilizing a Gemco 3ft3 Dryer/Bender 
  • Estimated Single Load – 280 lbs. X 3ft3 = 840 lbs. 
  • Initial value – 840 lbs. X $317.50 = $266,715.00

Scenario

A manufacturer is printing parts using the material and estimated value from above. Without recovery and reclamation, we have been told it is not uncommon for 60-70% of the initial raw material to be lost and or rendered unusable. Estimated value potentially lost to the floor then?  

60% – $160,029.00 or 70% $186,700.50  This is potentially on a single batch! 

Now imagine recovering 80%-90% of that and being able to reuse the material time and time again.  

This is what the AM-MPRR can do! 

With the estimated, one-time cost, of the Gemco Blender-Dryer ($320,000.00) and the addition of the VAC-U-MAX and Vorti-Siv ($500,000.00) creating the AM-MPRR, can you afford not to make the move to GEMCO?  








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