Improving Metal Powder Processing & Reclamation
The Challenge
The customer contacted Advanced Powder Solutions (APS), GEMCO’s sister company, to help them with the optimization of their metal powders and reclamation processes for 3D printing. APS is a facility that specializes in powder processing and contract manufacturing for various industries.
The customer produces powders for various industries, such as aerospace, medical, and automotive. Their products are used for 3D printing, plasma deposition, and other advanced processes.
The customer wanted to improve their powder quality and performance by reclaiming the material that was used for 3D printing. The reclaimed material was wet and partially fused, which created voids and gaps in the flow of the powders. This affected the accuracy and consistency of their 3D printing results and caused product quality and manufacturing issues for their customers. The customer’s innovative process involved breaking up the reclaimed material, drying it, and blending it with virgin material.
The customer suspected that the problem was related to the moisture content, blending uniformity, and flowability of their powders. They needed a reliable and efficient solution to dry, blend, and pulverize their powders to achieve optimal results. For that, they needed a knowledgeable partner.
The Solution
APS has extensive experience and expertise in handling various types of powders, including metals, ceramics, polymers, and minerals.
APS offered to test the customer’s powders using state-of-the-art GEMCO equipment.
The customer sent four batches of their powders to APS for testing over the last 12 months. The batches included virgin material, reclamation material, and different blends of stainless steel and other components. The reclamation material was different from the virgin material because it was wet and partially fused after being used for 3D printing. APS tested the customer’s powders using their 3 CF Formulator, a versatile machine that can perform multiple functions in one unit. The Formulator can blend, dry, pulverize, and discharge powders under controlled conditions, and operate at high temperatures up to 475 degrees Fahrenheit.
APS followed the customer’s specifications and instructions for testing their powders. APS also took safety measures to prevent any fire or explosion hazards due to the combustibility of metal powders. APS purged the machine with nitrogen gas and discharged the powders under a nitrogen atmosphere. APS also used grounding wires and personal protective equipment (PPE) to ensure safe operation.
The Results
The customer was very satisfied with the results of the testing done by APS, even though they expected a higher temperature (their idea was to dry powders at 525 degrees). They learned that they did not need to operate at very high temperatures to achieve their desired results. They also found that uniform blending and dryness had a greater effect on flowability than temperature.
They observed that their powders had improved quality and performance after being processed by the Formulator. Their powders had lower moisture content, higher blending uniformity, better flowability, and more consistent color. Powders also flowed better through the nozzle of their 3D printer, resulting in more accurate and precise printing results.
Conclusion
APS is a trusted partner for powder processing solutions, and they have demonstrated their expertise, experience, and customer service skills.
If you are looking for a reliable and high-quality powder contract manufacturing facility, contact APS today to get a quote and learn more about their capabilities.
