-Stress test under real production conditions – Beta testers highly impressed -F1 and D1 from AM Solutions redefine SLS automation

In 2024, AM Solutions - 3D post processing technology presented its first development stage for automated unpacking and powder handling. The system was created in close cooperation with EOS, one of the world's leading providers of industrial 3D printing technology. One year later - just in time for Formnext 2025 - the results are clear: both systems have proven themselves impressively in beta testing under real production conditions, delivering significant gains in profitability, efficiency, process reliability, and user convenience.

Formrise tests the F1: Powder preparation as a key process
Formrise, based in Töging am Inn, is the first beta test partner for the new F1 from AM Solutions - 3D post processing technology. The company was specifically looking for a suitable solution for powder preparation - a process that plays a decisive role in the quality of all subsequent additive manufacturing steps. After each build job, used powder must be refreshed with approximately 30 to 50 percent new powder, depending on the material type. If this step is not carried out precisely, it can lead to machine downtime, part breakage, uneven surfaces, or color deviations. Errors at this stage can therefore impact the entire downstream process chain.

Automated, precise, and repeatable
With the F1, AM Solutions offers a 2-in-1 system that combines powder sieving and mixing in one unit. The mixing ratio between used and new powder can be flexibly and precisely adjusted with a dosing accuracy of ±2%, ensuring consistent high quality. Previously, powder at Formrise was manually weighed and mixed using sieve trolleys - a time-consuming process with a high risk of incorrect mixtures or contamination. Assigning the wrong blend to a silo could render several hundred kilograms of powder unusable.

The F1 fully automates this critical process step. Up to 45 kilograms of powder per hour can be automatically mixed, increasing throughput by more than 30%. The mixing process takes place in small 1.5 kg batches, significantly reducing both mixing time and static charge. As a result, the resting time of the powder decreases from two to three days to a maximum of twelve hours. Thanks to the integrated ultrasonic sieve, the proportion of new powder could also be reduced by up to five percent.

Efficiency and growth without additional labor costs
At Formrise, the F1 is connected to eight printers with different build volumes. At full capacity, around 380 kilograms of powder are currently required per week. Operator effort is minimal: after filling the used and new powder silos, all further steps run automatically. This allows production volumes to increase without the need for additional personnel.

Reducing the proportion of new powder while maintaining consistently high quality also lowers unit costs and contributes to more sustainable resource use. In addition, the closed system ensures a high level of occupational safety by completely eliminating direct contact between operators and powder.

D1 optimizes post-processing in Switzerland
The D1 unpacking solution has also successfully passed its industrial field test. A Swiss medical company operating more than ten polymer 3D printers is using the system as part of the beta program to automate manual unpacking and make post-processing more efficient.
Before implementing the D1, all parts were unpacked manually. With the new fully automated solution, unpacking time for a full build job with high part density is reduced by half. The operator now only needs to load and unload the system - cutting labor time by up to 80% and freeing resources for other tasks. At the same time, productivity increases noticeably while unit costs decrease. In addition, the D1 impresses with its highly innovative and gentle part-handling concept, ensuring the same low scrap rate as manual unpacking, while delivering a significantly more efficient process.

Clean, safe, and flexible operation
Parts unpacked with the D1 can be transferred directly into subsequent post-processing steps such as blasting - no manual rework required. The closed process protects operators from powder contact and significantly reduces dust exposure. The D1 also allows for individual adjustment of different powder recovery rates, tailored to the specific build job. The intuitive HMI guides the operator clearly through the unpacking process, while the color-coded status list displays the current processing stage at all times.

During testing, it became clear that the parts don't need to be fully cooled before automated unpacking. Depending on part geometry and build density, this saves up to eight to ten hours of waiting time. The temperature drops reliably without affecting any of the system's components.

Close collaboration throughout the beta program
The cooperation between AM Solutions and the respective beta partners was characterized by intensive exchange. Weekly feedback rounds, software adjustments, and on-site technical support played a decisive role in integrating the systems seamlessly into existing production environments. Both beta testers were so convinced by the results that they decided to permanently integrate the systems into their production processes.

The real-world field tests clearly demonstrate: the F1 and D1 automate key process steps, increase both profitability and efficiency, and deliver greater safety and repeatability along the additive manufacturing process chain. Together, they mark a significant step toward fully automated, serial-ready SLS production.

For further information please go to: www.solutions-for-am.com

For over 90 years, the privately owned Rösler Oberflächentechnik GmbH has been actively engaged in the field of surface preparation and surface finishing. As global market leader, we offer a comprehensive portfolio of equipment, consumables and services around the mass finishing and shot blasting technologies for a wide spectrum of different industries. Our range of about 15,000 consumables, developed in our Customer Experience Centers and laboratories located all over the world, specifically serves our customers for resolving their individual finishing needs. Under the brand name AM Solutions, we offer numerous equipment solutions and services in the area of additive manufacturing/3D printing. Last-but-not-least, as our central training center the Rösler Academy offers practical, hands-on seminars to the subjects mass finishing, shot blasting and additive manufacturing. The Rösler group has a global network of 15 locations and approx. 150 sales agents.
For more information, please go to: www.rosler.com