voxeljet, Dressler Group GmbH, Fraunhofer IPA and the University of Bayreuth Collaborate in Re-Processing of Discarded PA12 Powder for 3D Printing via High-Speed Sintering (HSS)
Circular economy marks major milestone: recycling nylon waste powder in 3D printing, addressing up to fifty percent of running costs
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Figure 2 – Printed parts from reconditioned PA12 waste powder (Dressler Group) on voxeljet VX200 HSS, Source Fraunhofer IPA
The Challenge: PA12 Powder Degradation in Selective Laser Sintering (SLS) Systems
In SLS systems, unprinted PA12 powder loses its ability to be reused due to high temperature exposure in the build area, which causes the polyamide chains to lengthen after condensation, negatively affecting powder flowability and melt viscosity. This makes the material difficult to process again via laser-based technologies, as the energy input from lasers is too short to process longer molecule chains accordingly. Therefore, comparably high powder refresh rates are necessary, accumulating waste and associated high disposal costs.
The collaborative study aimed to reclaim this used powder by processing it through voxeljet’s VX200 HSS platform. HSS technology, using an inkjet-based printhead and infrared (IR) heating, offers selective and thermally gentler energy input, allowing the polyamide to sinter gradually, enabling the reuse of this powder. This means a real tribute to circular economy in Additive Manufacturing.
Dressler Group, experts in powder design and manufacturing, processed the used PA12 powder to homogenize and recover key powder properties such as flowability and moisture, making it suitable for reuse in HSS.
“Recycling used PA12 powder can effectively reduce costs and support sustainability efforts in AM,” says Dr. Ing. Holger Leonards, Head of R&D at Dressler Group. “Our expertise in regenerating powder properties and handling of large powder volumes enables companies to reclaim this valuable material.”
“The VX200 HSS technology is an open-source system, allowing us to quickly change and adapt process parameters to any powder,” says Jan Kemnitzer, Research Team Lead at Fraunhofer IPA and adds “We were therefore able to quickly adapt the 3D printer to the material with consistent or improved results in part properties.”
“The results of this study are especially interesting for ink and printhead based technologies such as the HSS technology. The future possibility of processing this recycled powder on production platforms like the VX1000HSS will bring immense cost savings,” says Tobias Grün, Global Product Management at voxeljet. “Typically, 50 % of the running costs are attributable to powder costs. Thus, this development provides a huge effect on cost effectiveness while boosting a circular material flow, reducing waste.”
A Sustainable Solution for Additive Manufacturing
This study highlights the growing issue of excess PA12 waste powder within the additive manufacturing industry. By reclaiming this material for use in voxeljet’s HSS technology, companies can reduce waste, lower operational costs, and improve sustainability in their additive manufacturing processes.
First parts of this collaboration will be shown at the formnext trade show in
ABOUT VOXELJET
voxeljet’s roots reach back to the year 1995 with the first successful dosing of UV-resins. In the context of a "hidden" project, initial 3D-printing tests were performed at the Technical University Munich. Our company was founded on May 5, 1999 as a spin-off from TUM in
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ABOUT DRESSLER GROUP - THE GRINDING AUTHORITY
Since its foundation in 1978, Dressler Group has specialised and been comprehensively certified in the grinding and finishing of plastics for all key industries. At the same time, DG has always undertaken research and development. Our core values are quality, flexibility, innovation and service. As a long-term systems partner and problem-solver, DG is involved in customer processes from the outset, offering all types of grinding and complete warehousing, packaging, customs and shipping logistics from a single source. Both gram-based test grinding and individually specified large quantities are available – always exactly reproducible and just in time. With the Listen-Care-Evolve approach, we adapt to each customer’s needs, from standard grinding to custom further development. Visit www.dressler-group.com for further information.
ABOUT FRAUNHOFER IPA
With nearly 1 200 employees, the Fraunhofer Institute for Manufacturing Engineering and Automation, Fraunhofer IPA, is one of the largest institutes in the Fraunhofer-Gesellschaft. The total budget amounts to
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voxeljet PR/ Media:
Frederik von Saldern
Tel: +49 821 7483 447
frederik.vonsaldern@voxeljet.de
voxeljet Applications
Tobias Grün
+49 821 7483 454
tobias.gruen@voxeljet.de
Dressler Group PR
Claudia Rosenberger
Tel: +49 172 522 1399
Rosenberger@dressler-group.com
Dressler Group R&D
Dr.-Ing. Holger Leonards
Tel: +49 2225 9204 43
leonards@dressler-group.com
Source: voxeljet AG