-Significantly improved surface quality with 25% time savings -Stratasys relies on the S1 from AM Solutions for optimized post-processing at its Technology Center in Rheinmünster

Stratasys, one of the world's leading manufacturers of additive manufacturing systems, is using the S1 from AM Solutions - 3D post processing technology, a brand of the Rösler Group, at its Additive Manufacturing Center in Rheinmünster. With this system, the company significantly improves the surface quality of its parts produced using the SAF process, achieving uniform and reproducible results. At the same time, the S1 enables a combined 2-in-1 process for the first time: cleaning and surface finishing in a single step, within one machine, using one media. This increases efficiency, reduces floor space requirements, and lowers operating costs.

Post-processing plays a key role at the Additive Manufacturing Center in Rheinmünster, where parts are produced for various industries such as automotive, medical, aerospace, and defense across the entire EMEA region - from prototypes and tooling components to end-use parts, whether for customer samples, trade shows, or as backup prints in case of technical issues. For Stratasys, post-processing is a crucial step in establishing additive manufacturing as a truly industrial production technology. "While the printing process itself is already highly automated, many post-processing steps remain time-consuming and partly manual. Automated solutions make it possible to standardize these processes, reduce lead times, and ensure consistently high, reproducible quality," explains Dennis Kronimus, Additive Manufacturing Center Manager, Stratasys EMEA.

Better surfaces and 25% time savings with an integrated 2-in-1 process
Especially for components produced using the SAF process, post-processing plays a crucial role. SAF (Selective Absorption Fusion) is Stratasys' powder-based additive manufacturing technology, designed for industrial-scale polymer part production. As it enables large batches of components with excellent mechanical properties, efficient and repeatable post-processing is essential to achieve consistent surface quality. Until recently, Stratasys used an automated cleaning solution from another supplier that relied on glass beads - without any additional surface finishing. While the process had long proven functional and reliable, it eventually reached its limits as quality requirements increased. The decision in favor of the S1 from AM Solutions was driven by its significantly improved surface quality and the resulting benefits for downstream processes such as dyeing. At the same time, the system impresses with a well-thought-out design that greatly simplifies maintenance and day-to-day operation.

In addition to improved part quality, the S1 also delivers clear economic benefits.
"Thanks to the S1, we can now perform cleaning and surface finishing in a single cycle using just one media - previously we needed two separate systems for this. As a result, we have significantly increased the efficiency of our SAF post-processing, achieving a 25% time savings along with better surface finishes. Furthermore, the system requires considerably less floor space - an important factor in our technology center, which houses numerous machines," says Dennis Kronimus.

Whereas the previous cleaning process used glass beads, the S1 now operates with polybeads, which are more durable and deliver a significantly better surface finish. The longevity of the blasting media is further enhanced by the S1's sophisticated media conditioning system. Filters, cyclones, and media screens are perfectly coordinated to reliably separate the blasting media from the powder.

Use of the C1 and PowderEase™ T1 highlights a strong partnership
In addition to the S1, Stratasys also uses the jointly developed PowderEase™ T1 at its Rheinmünster site. Designed specifically for the H350 SAF printer and manufactured at AM Solutions' facility in Untermerzbach, the system combines automated unpacking, powder recovery, and dosing for up to six printers. This significantly reduces manual labor while improving operator safety and powder recovery - a clear economic and environmental advantage.

Stratasys also utilizes the C1 from AM Solutions for the automated removal of support material from 3D-printed parts produced using PolyJet and industrial FDM processes. According to the company, the solution enhances workplace safety, while the process fluid requires far less frequent replacement than with other systems, thanks to continuous sieving. Coarse support structures can be removed from the bath without being dissolved.

Collaborative Partnership
Key reasons for Stratasys' choice of AM Solutions include not only the convincing product portfolio but also the company's decades of experience in surface finishing, backed by the Rösler Group. Stratasys especially appreciated the ability to test its own parts directly on-site and evaluate the results immediately. The straightforward collaboration and fast response times were also decisive factors.

Commenting on the deepening partnership, David Soldan, Head of AM Solutions - 3D post processing technology, states: "We are very pleased that our successful collaboration with Stratasys - which began with the development and implementation of the PowderEase™ T1 and the adoption of the C1 - has now been further strengthened with the integration of the S1. For us, this is a strong sign of mutual trust and proof that two companies with the highest quality standards can together achieve real progress in industrial additive manufacturing."

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