The 3D printing industry has grown rapidly in recent years, with its recorded market size of $20.68 billion in 2023 to $24.61 billion in 2024. This growth is expected to continue as the projections indicate that by 2033, the 3D printing market will reach around $117.78 billion with a compound annual growth rate (CAGR) of 19% between 2024 and 2033. 1 However, this growth can be even more impressive if challenges related to time-consuming and labor-intensive post-processing tasks are rectified. The post-processing tasks, such as cleaning, sanding, and finishing, often consume a considerable portion of the overall production time, impacting efficiency and profitability.

This challenge has been taken head-on by AM-Flow, a leader in automation technology focused on automating the post-processing workflow, specifically in sorting, to bring scalability to the 3D printing sector. Feeding, identification, sorting, quality control and bagging are all essential yet labor-intensive parts of post-processing, which often leads to production delays and inconsistencies. AM-Flow offers a solution by streamlining the sorting process to improve speed, scalability, and cost-efficiency. This article explores how AM-Flow's post-processing automation solutions are transforming the 3D printing landscape.

Overview of Sorting Post-Processing in 3D Printing

A 3D printing workflow starts with the design phase, where a digital model is created using CAD software. This model is then exported in a compatible format, like STL or OBJ, and imported into slicing software, where the model is converted into layers and tool paths, with parameters like print speed, temperature, and material type being defined. The slicing software generates a G-code file that guides the printer during production. After that, the actual printing starts by depositing the material layer by layer to build the 3D object. 

After printing, the part enters the post-processing phase, which may include removing supports, sanding, and polishing to enhance the surface finish. However, particularly the sorting of parts in post-processing, presents several challenges. For instance, in additive manufacturing, once a batch of parts is printed, they require cleaning and sometimes surface treatment or finishing. These parts, produced in large quantities, often vary in shape, size, material, and complexity, which makes manual sorting laborious and error-prone. 

Innovating Automation for Enhanced 3D Printing Post-Processing

When production scales up, the manual sorting process becomes unsustainable, leading to higher operational costs and lower productivity. Therefore, manufacturers struggle to meet high demand efficiently without automation while maintaining product quality. In this regard, AM-Flow's multi-faceted solution automates the workflow between several post-printing steps, providing a comprehensive approach to streamlining the sorting process and improving overall efficiency.

AM-Flow is a cutting-edge automation company that provides solutions for the additive manufacturing industry and has developed a range of innovative technologies designed to optimize the post-processing workflow in response to the unique challenges faced by 3D printing companies. AM-Flow specializes in automating the feeding, identification, sorting, quality control and bagging of 3D printed parts.

AM-Flow utilizes advanced technologies like computer vision, artificial intelligence, and robotics to provide post-processing solutions. Their complete suite of solutions addresses various stages of the post-processing workflow, from sorting and identifying parts to packaging and transporting them within production environments. 

Step-by-Step: How Automation Technologies Work in 3D Printing Post-Processing

1.    System Installation and Integration

AM-Logic serves as the base of AM-Flow's post-processing automation, integrating with the client's existing Manufacturing Execution System (MES), which ensures a smooth flow of information and enables the system to stay updated with the latest orders, parts to be printed, and relevant specifications. This digital connection enables the automated system to receive data on builds and production requirements, significantly reducing manual intervention and ensuring that post-processing aligns perfectly with production goals.

2.    Import and Nesting of Builds

As parts and builds are nested and saved in the MES, they are automatically imported into the AM-Flow system, which allows the computer vision component of the system, known as AM-Vision, to scan, and identify parts based on specific parameters attached to each part and relay that information to the AM-Sort. AM-Vision uses sophisticated algorithms to analyze images of 3D-printed parts and extract relevant information such as geometry, size, and color. The system can accurately identify individual parts, even in complex mixtures, ensuring that they are sorted correctly and efficiently. 

3.    Operator Sorting Process

After a mandatory cleaning or blasting process which is typically required for powder bed technologies, the operator retrieves the parts ready to be sorted. The operator selects the relevant build (e.g., DD-MM-YYYY _ PRINTER1) and sets sorting criteria. The AM-Flow system provides a user-friendly interface that makes it easy for operators to input data and monitor the sorting process. Operators can select different sorting criteria based on the specific requirements of the production process, which ensures that the system is tailored to the needs of the individual manufacturing facility.

In addition to improving the sorting process, AM-Flow’s automation technology helps reduce constraints in build nesting, which can often limit the printer’s efficiency. By optimizing material usage and minimizing the need for segregating orders based on materials or processes, AM-Flow enables manufacturers to pack builds more effectively, reducing manual sorting complexity and operational delays. For more details on how this impacts overall productivity, visit AM-Flow’s website.

4.    Automating Identification in Post-Processing

AM-Vision represents a major leap in post-processing efficiency as this system can accurately identify 3D-printed parts based on their geometric features, such as shape, size, and color, using advanced computer vision and AI-driven image recognition algorithms. For instance, AM-Vision has the capability of processing up to 5760 parts in 8 hours, which significantly reduces the time and labor required for part identification and classification.

After identifying the part and checking the sorting criteria, AM-Vision passes the sorting information to AM-Sort, ensuring the correct flipper arm opens and pushes the part into its designated bin for that part or group of parts. This automation step eliminates the need for operator involvement at this stage. The adaptability of AM-Vision ensures it can integrate into any post-processing workflow, accommodating various materials, technologies, and part specifications with minimal disruptions.

5.    Sorting and Grouping Parts

AM-Sort is another key component of AM-Flow's automation that represents the ultimate automated sorting solution. AM-Sort receives instructions from AM-Vision on which flipper arm to activate for the scanned and identified parts. It consists of a single conveyor belt that begins at the entrance of AM-Vision and is solely responsible for directing parts to their designated bins. AM-Vision not only determines the correct path for each part, but also provides its precise position on the conveyor, ensuring the flippers open and close at the right moment.

After sorting, the parts re-enter the system as post-processed items rather than by their initial build characteristics. This process repeats until each part reaches its final stage of post-processing, at which point they are ready for bagging and labeling through the AM-Bagging module, which seamlessly integrates with AM-Sort exits. 

Enhancing Efficiency and Scalability in Post-Processing Workflows

Post-processing automation is becoming a critical factor in maximizing the efficiency and scalability of 3D printing operations. Addressing the labor-intensive and time-consuming nature of traditional post-processing is imperative for manufacturers to remain competitive. In this regard, AM-Flow has transformed post-processing by offering innovative solutions that automate key steps such as sorting, identification, and transportation of 3D-printed parts. AM-Flow enables manufacturers to streamline their post-processing workflows, reduce costs, and improve scalability by utilizing AM-Flow's advanced technologies like AI-driven computer vision, robotics, and seamless system integration.

Optimize Your 3D Printing Operations

As the additive manufacturing industry advances further, 3D printing companies should consider AM-Flow's solutions for streamlining their post-processing in order to stay competitive in the evolving additive manufacturing landscape. Explore the AM-flow website or book a meeting with the team to find out how their solutions can help you optimize production, minimize delays, and enhance overall operational efficiency.

References

1. 3D Printing Market Size, Share, and Trends 2024 to 2033. [Online] Precedence Research. Available at: https://www.precedenceresearch.com/3d-printing-market (Accessed on October 7, 2024) AM-Flow. Available at:  https://am-flow.com/about-us/