Technology for Additive Manufacturing and 3D Printed Parts

Interview conducted by Mychealla RiceDec 12 2017

Current techniques for additive manufacturing and 3D printed parts are out dated and inefficient. In this interview Bob Bosinski, Vice President of Operations at PostProcess Technologies talks to AZoM about the Hybrid DECI Duo system and it benefits.

Please tell us a bit about PostProcess Technologies Inc. and the work you do.

PostProcess is the only company in the world laser-focused on addressing the post-printing problem in additive manufacturing. Contrary to what some may think, when parts leave a 3D printer, they are not customer-ready.

Our solution is a game-changer for the high timely consuming processes of surface finishing and support removal that are typically performed with ineffective techniques. The PostProcess combination of software, hardware, and chemistry works on all 3D print materials and technologies. Our solution is a key enabler to the additive manufacturing market reaching production scale levels.

What are the problems with current techniques such as manual labor and traditional finishing machines that are used for post-printing of additive manufactured parts? Why are they the least efficient?

These current techniques are short term, outdated solutions that do not enable customers to take full advantage of the advance manufacturing capabilities of 3D printing. With manual labor, there is usually consistency issues due to varying skill sets and experience levels. Therefore high quality, repeatable results are difficult to achieve.

Traditional subtractive manufacturing finishing solutions are not aligned with the advancement of 3D print materials and complex geometries, so there can be high damage rates.

These systems are low precision with legacy “on”and “off” controls that lack real-time feedback and intelligent adjustments based on the part type.

Lack of control with a traditional finishing control approach introduces the risk of damaging additive parts, especially those with fine feature detail.

You can imagine that it would be costly and cumbersome to scale a 3D printing operation as the company’s demand increases and they would like to build more parts.

The Hybrid DECI Duo System

Tell us how the PostProcess technique is different? How can it help?

PostProcess lets software control the process. Our proprietary AUTOMAT3D™ platform is the brains of our system, designed with different agitation levels to cater to a variety of geometries and enabling users to mix geometries into batches to save time and operate more efficiently.

We designed the hardware with user-friendly features and with the manufacturing floor of the future in mind.

Finally, our chemistries are developed in house and optimized for the advanced 3D print material. Bringing these three pieces together means the customer gets increased throughput and consistency with low damage rates and minimal technician attendance time.

Tell us about the Hybrid DECI Duo system? How does the Hybrid DECI Duo compare to other models on the market?

There’s no other system on the market that compares to the Hybrid DECI Duo. It automates two processes within one compact footprint, performing both support removal and surface finishing operations.

Where it really shines is finishing 3D printed advanced thermoplastics and metals that have internal channels, organic geometries, and honeycombs within minutes!

What are the benefits of PostProcess software for post-printing of 3D printed parts?

Our customers see dramatic increases in productivity as a result of using our automated software. We have cases where they spend 6-8 hours traditionally removing supports and reduce that to less than 5 minutes of technician time and one hour of process time, and with multiple parts per batch.

The software also drives a reduction in damage rates, as the agitation program is sensitive to the unique needs of 3D printed geometries.

How can the Hybrid DECI Duo be a benefit to Aerospace and Automotive applications?

Aerospace and Automotive markets are utilizing the most advanced plastics and metals, with stringent requirements for end part consistency and increasing scales of production. The Hybrid DECI Duo is designed with these materials in mind.

The Duo doesn’t get tired, can run unattended, and can process exponentially more parts for 3 shifts per day. Our customers tell us this results in significant productivity increase for their operations.

They can put their people on valuable activities instead of micro managing an old finishing machine or dealing with damaged parts.

The Hybrid DECI Duo is a benefits to aerospace applications. Image Credit: ArchMan/shutterstock.com

What does the Hybrid DECI Duo system mean for the future of the additive manufacturing industry?

The forecast in industrial 3D printing over the next 5 years is dramatic growth no matter which research report you read. When you couple the trend of increase in printer speed with demand, this necessitates looking at how every point of the supply chain will scale.

The Hybrid DECI Duo, along with our entire suite of systems, can remove the post-print bottleneck and open up 3D printing to reach its full potential.

Where can our readers go to find out more?

Visit us at postprocess.com, contact us at [email protected], or call 1.866.430.5354. We love to talk 3D printing!

About Bob Bosinski

Bob Bosinski, Vice President of Operations at PostProcess Technologies, is a start-up veteran, experienced in designing and deploying robust manufacturing processes and systems to enable rapid expansion.

Bob spent 24 years with AirSep Corporation, leader in medical oxygen supply solutions, from start-up through post acquisition, before coming to PostProcess.

Bob has a master’s degree in Industrial Technology.